Novel Technique for Enhancing the Strength of Friction Stir Spot Welds through Dynamic Welding Parameters

Presently, friction stir spot welding (FSSW) has become a common alternative for spot welding technologies. Over the years, researchers have implemented various methods for enhancing weld strength. However, the literature shows that the previously reported approaches have used static (constant) welding parameters set at the beginning of the welding stroke (i.e., the FSSW parameters were kept constant during the welding stroke). In contrast, in this study, an innovative technique is proposed for enhancing the weld strength for Al 1050 material by adjusting the FSSW process parameters during the welding stroke. Two FSSW parameters, namely, feed rate and spindle speed (dynamic parameters), are used in this study with a stepwise variation function and are changed during the welding stroke. The results of this study show that the weld tensile strength is enhanced by 12–21% when using the proposed novel dynamic welding parameter technique. This is a significant increase in the weld strength compared to when static welding parameters are employed during the welding stroke.