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Stud joints of 2017 aluminium alloy were friction welded and its joint strength was examined. A stair zone was formed at the weld interface. Although the hardness of the stair zone was almost the same as base metals, the heat-affected zone of the bar and the plate was softened. The tensile strength of joints tended to increase with a pressure and a friction time, and the highest tensile strength was 275 MPa (63.1% joint efficiency for the bar base metal). In the bending testing, joints were cracked in the weld zone at a bending angle of less than 5°. In the fatigue testing, joints fractured near the weld interface and the fatigue strength of joints increased as the tensile strength of joints was high.

Conferring lightweight and good corrosion resistance, aluminium alloy joints are extensively required in the manufacture of various types of electrical and mechanical components. Research data previously obtained by the authors1, 2 show the efficiency of friction-welded joints, regardless of whether produced from similar or dissimilar materials, to be fairly well scattered under identical sets of friction welding conditions and underline the need for statistical analysis of a large number of joints to determine the suitability of any specific set of friction welding conditions. That is to say, joints with a high mean joint efficiency that are friction-welded under optimum friction welding conditions conform to a normal distribution with low scatter during such statistical analysis while simultaneously showing a large Weibull distribution shape parameter and small dispersion. On the other hand, joints with a low mean joint efficiency that are friction-welded under unsuitable friction welding condi...

(2004). The formation of intermetallic compounds in aluminium alloy to copper friction-welded joints and their effect on joint efficiency. Welding International: Vol. 18, No. 7, pp. 516-523.

Friction welding of S15CK carbon steel was carried out in order to examine the relationship between heat input for welding and joint strength. The joint strength is evaluated from tensile strength. The heat input is a heat source for welding solid materials and was classified into 6 inputs: friction heat input, deformation heat input and total heat input in the friction stage and upset stage.The most important heat input for evaluating the joint strength among these heat inputs was experimentally investigated through the tensile strength of joints welded under various welding conditions.As a result, it was made clear that the deformation heat input in the upset stage is much strongly related with the joint strength, and sound weld joints can be obtained deformation heat inputs more than about 100J/s. Moreover, it was recognized that the joint strength is possible to evaluate by the upset loss, therefore, sound welded joints can be obtained with about 1.2 mm upset burn-off length or more also.