Abstract Friction stir spot welding (FSSW) is one of the effective solid-state welding strategies to achieve good joint efficiency between dissimilar aluminum alloys. However, the formation of tool-induced keyhole (a stress raiser) is inevitable during the FSSW process. This study explores the possibility of eliminating keyhole with the aim of improving the properties of the joint by Modified Friction Stir Clinching (MFSC) process. The tensile-shear and cross-tension strengths of the MFSC joints are 83% and 50% higher than that of the specimens joined by FSSW. The article presents a comprehensive analysis of the material flow characteristics, microstructural evolution, and tensile properties of the dissimilar joints between AA2024-T3 and AA6061-T6 that was enabled by the MFSC process.

中文翻译：

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AA2024-T3和AA6061-T6异种接头的改进搅拌摩擦铆接工艺开发与表征

摘要 搅拌摩擦点焊（FSSW）是一种有效的固态焊接策略，可在异种铝合金之间实现良好的连接效率。然而，在 FSSW 过程中，工具引起的锁孔（应力升高）的形成是不可避免的。本研究探讨了通过改进摩擦搅拌铆接 (MFSC) 工艺消除小孔以提高接头性能的可能性。MFSC 接头的拉伸剪切和横向拉伸强度比 FSSW 连接的试样高 83% 和 50%。本文对 MFSC 工艺实现的 AA2024-T3 和 AA6061-T6 之间不同接头的材料流动特性、微观结构演变和拉伸性能进行了综合分析。