Wear mechanisms and failure analysis of a tool used in refill friction stir spot welding of AA6061-T6

Investigating tool wear in refill friction stir spot welding (RFSSW) is essential for understanding its limitations and improving its efficiency. Increasing the tool's service life is important to push the technology's readiness level and transfer the technology from the laboratory to industrial applications. In this study, the quasi-static lap shear performance of AA6061-T6 similar welded spots was investigated and tool wear was continuously monitored until tool failure at 3450 welding cycles. Furthermore, the fundamentals of the wear mechanisms in RFSSW were further elucidated. The investigation shows that it is possible to achieve steady quasi-static lap shear performance of the spot welds over advancing tool wear by adjusting the heat input to compensate for losses in frictional heat generation efficiency (related to tool profile changes by abrasion). A subsequent tool failure case analysis showed the main causes for the continuous wear degradation of the shoulder. Tool wear was driven by plastic deformation of the hot-work tool steel and subsequent break-out of tool steel ridges, introducing big hard particles into the contact region between the moving and rotating tools. In addition, the formation and detachment of Fe-Al intermetallic compounds counteract with the rotating tools and increase tool wear. • The ultimate lap shear force remains stable at 7.7 kN until 3450 welded spots. • Increasing rotational speed can offset the reduced heat input caused by tool wear. • Higher rotational speed accelerates the tool's wear rate. • Additional heat input during idle due to the fracture of tool steel fragments. • Formation and fracture of Fe-Al intermetallic compounds contribute to tool wear.