Description Friction stir spot welding (FSSW) is an appropriate process to join materials that are difficult to weld using fusion welding methods. This process can meet the challenge of rapid improvement in automotive manufacturing, and may replace fusion welding in electric resistance welding and non-permanent rivet joints due to its solid-state nature and environmentally friendly aspects. This project will aim to develop a numerical model of FSSW in the finite element modelling (FEM) software Abaqus/Explicit. This model will be use to study the friction stir spot welding of selected dissimilar materials to evaluate the effect of process parameters on the joint quality and key dependent variables like torque and welding forces. Key Objectives

Undertaking a detailed literature review of dissimilar material FSSW Understanding of the FSSW process and its fundamental principles Developing an appropriate model of FSSW –in terms of minimum computational cost and reasonable results – that will predict defect formation and processed zone width Optimising the process parameters within the model to reduce both cost and effort of any relevant experimental work