In temperature forming of friction stir lap welds in aluminium alloys

The objective of such investigation is the study in depth of the forming phase of welds realized on three sheet metal blanks in aluminium alloys by friction stir lap welding. Such forming phase was performed by upsetting at different constant forming temperatures varying from 200°C to 350°C with constant ram velocities of 0.01 and 0.1 mm/s. The temperature values were obtained by the use of heating strips applied on the upper tool and on the lower tool. It was observed an increase in the friction factor, acting at the upsetting tool-workpiece interface, with increasing temperature that is very useful in producing the required localized deformation with which to improve the weld. It was also confirmed that the forming phase allows to realize a required thickness in the weld area allowing to neglect the surficial perturbation produced by the friction stir welding tool shoulder. The obtained thickness could be subjected to springback when too low temperatures are considered.