| Summary: | A three-dimensional finite element thermal-mechanical coupling model was developed to simulate the friction spot joining with a flat shoulder tool for AA6061-T6 Al alloy and carbon fiber reinforced polymer (CFRP) at different welding conditions. When joining at 1500 rpm rotation speed and 0.1 mm/s plunge speed, the peak temperature at the Al alloy-CFRP interface reached up to 575 °C as the plunge depth was increased to 0.6 mm. The interfacial temperature was reduced as rotation speed or plunge depth was decreased. Good correspondences between predicted temperature field distribution and experimental bonded area have been achieved. Thermal history and temperature distribution at the top surface of Al alloy were well validated by experimental measurements. The temperature zone within 220–340 °C made the greatest contribution to improving joint integral resistance to tensile-shear testing, which was recommended to enlarge during the process for a given welding parameter. On the basis, the design of tool structure enabling to reduce peak temperature and enlarging melted area was proved numerically as a feasible way to enlarge processing windows to increase the overall strength of joint. The findings could hopefully help optimize friction spot welded joints of dissimilar metals and composites.
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