Experimental study and numerical simulation of cellular I-beam manufactured using refill friction stir spot welding technology.

• The effectiveness of thin-walled cellular beams manufactured by RFSSW was developed. • A parameterized finite element model (FEM) of the cellular beam was developed. • Results of numerical simulations and experimental tests were compared. • A parametric FEM model of the cellular beam was developed in the ADINA system. • The numerical model was used to analyze beams with different cross-sections. The paper presents analyses of thin-walled I-beams constructed from 6061-T6 aluminum alloy using refill friction stir spot welding (RFSSW). A parametrized finite element model of the reference cellular beam was developed, and the results from numerical simulations and experiments were compared. Subsequently, the validated numerical model was utilized to conduct an in-depth analysis of three additional beams featuring distinct cross-sections. To assess the weld behavior, experiments were conducted on samples composed of two sheets connected by two spot welds. The outcomes of these investigations underscore the suitability of RFSSW as a method for constructing thin-walled structures in civil engineering applications. [ABSTRACT FROM AUTHOR]