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Refill Friction Stir Spot Welding (RFSSW)

Refill Friction Stir Spot Welding (RFSSW) is a solid-state welding process suitable for spot joining of lightweight metallic alloys [e.g., Aluminum and Magnesium alloys as well as polymer and composite materials.], which is a development of Friction Stir Welding (FSW). 

Unlike FSW, there is no traversing motion associated with the RFSSW process. 

This results in a localized ‘spot’ weld.

The welding tool consists of three parts: pin, sleeve, and clamping ring. 

By controlling the relative movement of the pin retraction and sleeve pressing down, there is a back-filling pressing process at the end of the welding process, pushing the base material back into the welding hole during the welding process.

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Refill Friction Stir Spot Welding

As a new type of spot welding technology, the welding process does not require current, and the RFSSW head has a stirring and crushing effect on the surface oxide film of aluminum alloy materials. 

At the same time, it can backfill the extruded material, eliminating the keyhole problem of traditional friction stir welding, thereby increasing the effective bearing area of the joint, improving mechanical properties, and prolonging fatigue life. 

It is widely used in manufacturing fields such as automobiles, shipbuilding, and aerospace.

The RFSSW process offers a number of advantages over current spot joining methods, especially for the joining of aluminium alloys. 

For example, RFSSW avoids many of the defects associated with melting and solidification of metals, owing to the material remaining in the solid-state; 

No filler material or third body is added to the weld, reducing component mass; 

No fumes, porosity or spatter are generated; and the process is easily automated, making it suitable for production.

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