About this Abstract |
| Meeting |
2026 AWS Professional Program
|
| Symposium
|
2026 AWS Professional Program
|
| Presentation Title |
High-Speed Double-Sided Friction Stir Welding of Automotive AHSS: Process Development and Practical PCBN Tool Life |
| Author(s) |
Muneo Matsushita, Rinsei Ikeda, Branislav Džepina, Richard Townsend |
| On-Site Speaker (Planned) |
Muneo Matsushita |
| Abstract Scope |
Double-sided friction stir welding (FSW) with a preheating process using high-frequency induction heating was investigated to enhance the travel speed for welding of automotive advanced high-strength steel (AHSS). Butt joints of 1.6 mm-thick, 1180 MPa-grade steel sheets were employed.
A maximum welding speed of 6.0 m/min was achieved without weld defects or lack of fusion, representing a 50% increase compared with the process without preheating and approaching the speed of laser beam welding, one of the primary joining methods in the automotive industry.
Metallographic observations revealed that plastic flow in the stir zone was reduced under steep thermal gradients, which became more pronounced at higher travel speeds. The preheating process effectively homogenized the temperature distribution, thereby promoting stable plastic flow and increasing the attainable welding speed.
Tool life evaluation was conducted for double-sided FSW without preheating using tools made of polycrystalline cubic boron nitride (PCBN). The tools operated without fracture up to 200 m, demonstrating robust durability. Stable weld quality was maintained up to approximately 100 m, indicating a practical tool life under the present conditions, while progressive wear beyond 120 m gradually affected weld appearance.
These results demonstrate the technical feasibility and industrial potential of double-sided FSW for high-speed, high-quality joining of AHSS, while the tool life evaluation highlights the applicability of PCBN tools. |
| Proceedings Inclusion? |
Undecided |