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You have full access to this open access article. Refill friction stir spot welding RFSSW is a highly flexible and promising solid-state joining method for aluminium alloys.
Alternatively, resistance spot welding RSW can be stated as an appropriate joining method which can be automated and used within a high-volume production due to short process times. Both processes do not need any additional elements and a flat surface on both sides of the joints can be realised.
In order to meet the modern requirements for crash safety and structural stiffness, thermal and mechanical joining methods are mainly combined by using single-component epoxy resin adhesives.
Due to an insufficient knowledge about the application of both thermal joining methods for the abovementioned material combinations combined with additional adhesives, deeper investigations were done regarding the interactions of the polymers and the joining processes. Starting with a brief presentation of the boundary conditions of the investigations and the refill friction stir spot welding and resistance spot welding of high-strength aluminium alloys with sheet thicknesses bigger than 5.
Afterwards, the paper discusses the influences of the process parameter on the metallographic joint formation and load-bearing capacities for a selected two-sheet and four-sheet material combination. When combining the spot welding technologies with adhesives, the process parameters of the RFSSW process have to be adapted for the two-sheet combination by adding a squeeze-out step, while for RSW, just the preholding time has to be increased.