{"title":"High-speed robotic friction stir lap welding of three stack aluminum alloy assembly for automotive applications","authors":"Hrishikesh Das, Shivakant Shukla, Piyush Upadhyay","doi":"10.1016/j.mfglet.2025.06.200","DOIUrl":null,"url":null,"abstract":"<div><div>We present the first experimental demonstration of high-speed (1 m/min) robotic friction stir lap welding for three-sheet (3T) stack-ups of both similar and dissimilar aluminum alloys, including wrought and cast forms. The mechanical performance of the joints under lap shear, T-peel, and U-peel/KSII loading were evaluated. A novel U-peel/KSII configuration, applied for the first time for linear joints demonstrates the role of stitch welds in arresting crack growth. These results establish the feasibility of using robotic FSLW for complex, high-volume automotive structures while maintaining high weld quality at industrially relevant speeds.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 36-40"},"PeriodicalIF":1.9000,"publicationDate":"2025-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Manufacturing Letters","FirstCategoryId":"1085","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2213846325002391","RegionNum":0,"RegionCategory":null,"ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
Abstract
We present the first experimental demonstration of high-speed (1 m/min) robotic friction stir lap welding for three-sheet (3T) stack-ups of both similar and dissimilar aluminum alloys, including wrought and cast forms. The mechanical performance of the joints under lap shear, T-peel, and U-peel/KSII loading were evaluated. A novel U-peel/KSII configuration, applied for the first time for linear joints demonstrates the role of stitch welds in arresting crack growth. These results establish the feasibility of using robotic FSLW for complex, high-volume automotive structures while maintaining high weld quality at industrially relevant speeds.