| About this Abstract |
| Meeting |
2024 AWS Professional Program
|
| Symposium
|
2024 AWS Professional Program
|
| Presentation Title |
Advances and Challenges in Friction Stir Lap Welding for High-strength Aluminum Automotive Components |
| Author(s) |
Piyush Upadhyay, Hrishikesh Das, Shivakant Shukla, Mitch Blocher, Jorge F Dos Santos |
| On-Site Speaker (Planned) |
Piyush Upadhyay |
| Abstract Scope |
The use of high-strength Al alloys in thicker gauges can enable car components and assemblies that can be viable alternatives to steels, thereby maintaining lightweight architecture as the auto industry ventures towards the mainstreaming of EVs. Established joining technologies are being pushed to the limits as both the substrate thicknesses and strengths increase. Friction Stir Lap Welding (FSLW) can be a viable alternative that can produce multi-sheet joints without the need for third-body fasteners. In the form of Short stitches, FSLW offers the flexibility for greater component design adaptability while long continuous FSLW can serve as effective seals and provide higher throughput in assembly. PNNL has been developing 3T dissimilar Al joints in coupon and near-component levels. Process developments have been carried out in stiff gantry systems and a flexible robotic platform. Thus far, viable three-sheet FSLW joints have been demonstrated at a welding speed of 1m/min (pin length of 5mm+) for sheets containing high strength 7xxx, 6xxx, and some cast alloys. This presentation will highlight the challenges and opportunities associated with robotic FSLW for flat and stamped parts, with a specific focus on dissimilar joints. |
| Proceedings Inclusion? |
Undecided |