Joining of Aa1050 Sheets Via Two Stages of Friction Spot Technique

The aim of this work is to improve the shear force of AA1050 sheets joint’s using two stages of friction spot technique by spot extruding of aluminium metal. The primary and secondary stages were carried out using two different tools: a pin with shoulder tool and a pin-less tool in the primary and secondary stage, respectively. Effect of the depth of plunging and tool rotating speed on joint’s properties were analysed. Increasing the depth of plunging and tool rotating speed increased the depth of the extruded aluminium. The tool plunging depth was the maximum influential parameter on the depth of the extruded aluminium. The secondary stage improved the joint’s shear force. The tool rotating speed exhibited the most effective parameter on the process temperature, joint’s shear force, and pull-out. The joint’s shear force and pull-out decreased with increasing the depth of plunging and tool rotating speed. The two sheets are joined by a mechanical interlock at a line of an interface by a flow of the extruded aluminium without defects. The tested samples were failed by different modes: shearing the extruded aluminium and cleavage the aluminium metal near tool trace.