In this paper an analysis of Friction Stir Spot Welds (FSSW), applied to lap joint aluminum alloy is presented. The analyses regards the structural behavior of FSSW joints in order to assess the failure mode and its dependence on mechanical properties distribution of the sheets material and, consequently, on process parameters.

FSSW joint is analyzed by means of a complex 3D FE model, which allows to evaluate, in a parametric manner, the multifaceted internal geometry of the joint and the actual distribution of material mechanical characteristics after welding. Experimental tests allowed to verify the results and to calibrate the material characteristics in the FE model.

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