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Title page for ETD etd-03042014-142014

Type of Document Dissertation
Author Cox, Chase Davison
Author's Email Address ChaseDCox@gmail.com
URN etd-03042014-142014
Title Friction Stir Spot Welding: Engineering Analysis and Design
Degree PhD
Department Mechanical Engineering
Advisory Committee
Advisor Name Title
Dr. Alvin M. Strayss Committee Chair
Dr. David R. DeLapp Committee Member
Dr. George E. Cook Committee Member
Dr. Greg Walker Committee Member
Dr. Jason Valentine Committee Member
  • friction stir spot welding
  • friction stir welding
  • FSSW
  • FSW
  • aluminum
  • spot
  • welding
Date of Defense 2014-02-28
Availability unrestricted
Friction stir spot welding (FSSW) presents automotive manufacturers with a process that is capable of joining light-weight aluminum alloys. The desire to eliminate the keyhole, a product of the process, is the main motivation of this dissertation. It is found that using a pinless tool offers a simple, low-cost, option capable of creating spot welds without the keyhole. The research presented in this dissertation, both experimental and numerical, greatly expands upon what was a limited understanding of the friction stir spot welding process (with a pinless tool especially.) The result of this work is a more fundamental understanding of the welding process, its parameters, and how they interact to affect the quality of the spot weld. A novel double-sided variation of the FSSW process is presented. In order to create double-sided friction stir spot welds a rotating anvil is designed, built, and experimentally qualified. The double-sided FSSW process is found to reduce cycle times and process forces, improve weld quality, and increase the maximum workpiece thickness that can be welded with a pinless tool.
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