2D Axisymmetric Modeling of RFSSW Repair and Experimental Validation

Refill friction stir spot weldingRefill friction stir spot welding (RFSSW) is a solid-state spot joiningJoining technique that can be used to weld aluminum alloysAluminum alloys in various thickness and alloy combinations. From a production perspective, there are times when RFSSW can be terminated prior to completion, leaving an area in need of repair. It is critical to identify the unique conditions that yield excellent bonded properties and the ability to repair a joint that was interrupted during the welding process. Qualified repair techniques are critical for successful implementation of a welding process for use on large weldments with a significant number of spot joints. The focus of this work is to demonstrate a repairRepair technique for RFSSW that can be validated both experimentally and numerically. Modeling is performed using a 2D axisymmetric, thermo-mechanically coupled modelModel, which has previously been validated for the RFSSW joiningJoining process. Repaired properties are shown to exceed 90% of the original mechanical propertiesMechanical properties of the RFSSW process.