Welding between ADC12 and SS400 was successfully performed by friction stir diffusion process. The experiments were conducted by a machining center with a cemented carbide tool and welding conditions, such as a rotating speed, welding speed and position of the tool, were optimized. By plunging the rotating tool into the interface with offset, ADC12 and SS400 were welded above 2000 rpm of the rotating speed at the welding speed of 50mm/min. Tensile strength was evaluated for the welded specimens. The specimens fabricated above 5000rpm in the rotating speed were fractured at the weld zone and showed relatively low tensile strength. The specimens, on the other hand, made between 2000 and 4000 rpm were fractured in the portion of the base aluminum alloy. Achievement of more than 100% in joint efficiency was indicated in the present friction stirring process.
The possibility of a welding between ADC12 and SS400 by means of friction stirring was fundamentally clarified. The primary process parameters, such as a rotating speed, rotating direction of rod and offset of pin periphery from materials interface were optimized, respectively. The welding was performed only in the clockwise rotating direction while that was not in the counter clockwise. Too large figures of the rotating speed failed in the welding due to the broken of rod itself. Optimum condition in the offset of pin periphery from the interface was given as it is on the interface or inside of the hard material. Consequently, the welded joints showed higher tensile strength than that of the base aluminum material when the welding was pursued under the moderate conditions. Intermetallic compound phase was not detected obviously at the interface region of the welded joint. Welding mechanism between aluminum alloy and steel by means of friction stirring with clockwise rotating direction was proposed.
Friction stir welding (FSW) has become an important joining process of aluminum alloys in various industries. Conventional FSW process, however, is difficult to apply to the welding in dissimilar metals. In our series of research, the welding between aluminum alloy and steel has achieved by means of friction stirring. This is a promising way to realize a high performance joint in dissimilar metals. In the present study, the weldability between 6063 and S45C by means of friction stirring was investigated. By optimizing the welding conditions, such as a tool configuration and a rotating speed, higher welding speed more than 1000 mm/min was achieved. The mechanical properties of the weld joints fabricated were evaluated with the normal tensile test and hardness test. The specimens were fractured in the portion of the lowest hardness area in aluminum alloy. In the microstructure observation with SEM, thick intermetallic compound layer on the interface region was not detected.
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