Structures with dissimilar materials can make full use of the advantages of each material. However the welding of the aluminum alloy plate and plastic plate are difficult due to high difference in melting point. The friction stir lap welding method is selected in this paper. The numerical model was built to study the heat transfer behavior inside the plates, as the temperature plays an important role in determine the weld quality. The model was validated through experimentally measured temperature results. The influence of welding process parameters such as welding speed, tool rotating speed and downward feed was analyzed. It was found that under the welding speed of 100r/min and downward feed of 0.3mm/s, sound weld was produced.
Friction surfacing is a solid-state metal deposition technology, which has potential application in additive manufacturing. In this paper, multilayer of AA6061 deposition was fabricated on 316L steel plate by friction surfacing. The morphology, temperature field, axial force, microstructure, and mechanical properties of the deposition were analyzed. It was found that with the increase of substrate surface roughness, the thickness of deposition increased, the width decreased, and the bonding strength increased. The grain size increased and the hardness decreased from the top layer to the bottom layer of the deposition as a result of reheating by subsequent layer surfacing process. The bonding strength between the substrate and deposition decreased when the number of layers increased.
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