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Abstract
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In this paper, the mechanical behavior of single strap joints was investigated under tensile loading. Four sets of
specimens were fabricated e.g., adhesively bonded, friction stir spot welded (FSSW), adhesively bonded-FSSW
(AB-FSSW), and hybrid joints. The failure load of specimens subjected to lap shear tests was employed to
compare the load carrying capacity of the samples. L9 Taguchi design of experiment was used and the effects of
FSSW parameters e.g. tool rotational speed (RS), plunge rate (PR), and dwell time (DT) on the failure load of the
specimens were investigated. It was found that the welding parameters of RS = 1600 rpm, PR = 8 mm/min, and
DT = 30 s leads to the highest failure load (FL) of FSSW joints, and applying the adhesive increased the joints
failure load capacity up to 80%. By comparing the Scanning Electron Micrographs (SEM) images of the FSSW
joints, it was revealed that a specimen with the maximum failure load has a homogeneous microstructure. The
finite element method was developed to estimate the failure load of different joint types. It was observed that the
numerical results are in good agreement with the experimental data with errors of less than 6%.
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