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A 2024-T3 aluminum alloy stud with the circular ridge projection at the bottom was welded to a 1.5 mm-thick 5052-H34 aluminum alloy thin plate by the advanced high-speed solid-state joining method. The projection crushed and spread along the plate surface. Joining was achieved within a few milliseconds with a negligible temperature increase of the joint. Asymmetrical deformation occurred on both the inner side and the outer side of the projection. It was found that enlargement of the joining area outside of the projection was effective to increase the joint strength by the present authors’ previous study. Based on this guide, in the present study, trial was made to increase the joint strength by determining the optimum projection shape at a bottom of the stud. Three types of projection shape were prepared and they were provided for joining tests at various discharge voltage conditions, and joint interface morphology, joining area and joint strength were compared. When we used the stud with which the projection tip shifted to the inner side, the outer side of the projection spread much wider along the plate surface than the inner side. This worked effectively to increase the joint area of the outside and the resultant joining strength. It is confirmed that the modified projection shape is useful for the stud welding for the thin plate. (Received December 22, 2011 Accepted May 23, 2012)

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Projection shape modification for improvement in joining strength of high-speed solid-state joined 2024 aluminum alloy stud and 5052 aluminum alloy thin plate