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Light weight design is believed one of the most effective ways to enhance performance, reduce fuel consumption and harmful gases for air and land vehicles. Hence, welding lightweight metals like magnesium alloys is very important. Friction stir spot welding joints of 2 mm thick AZ91 magnesium alloy sheets by overlapping two of them were performed utilizing two welding tools having conical and triangular pin at 800, 1200 and 1600 revolution per minute (rpm) tool rotational velocities for each tool to identify the pin shape and rotation speed impact on microstructure and mechanical features of the created joints. The stir zones of the joints contained smaller grains, therefore had higher hardness in comparison to AZ91 base metal, thermo-mechanically affected zone (TMAZ) and heat affected zone (HAZ). The lowest hardness values were found in HAZ of the welds. Hardness fell slightly with a rise in rotation speed for both tools because of more heat input. Strength of the joints manufactured applying the triangular pin tool was better because this pin mixed materials better, thus created joints with bigger welding area and greater hardness. The strongest weld was fabricated by applying triangular pin tool and 1600 rpm.

Influence of tool pin shape and rotation speed for friction stir spot welding of AZ91 magnesium alloy sheets