Dissimilar friction-stir welding of 430 stainless steel and 6061 aluminum alloy: Microstructure and mechanical properties of the joints

Zandsalimi, Sirvan; Heidarzadeh, Akbar; Saeid, T.

doi:10.1177/1464420718789447

Cited by 27 publications

(18 citation statements)

References 26 publications

(42 reference statements)

Supporting

Mentioning

Contrasting

Order By: Relevance

“…This is consistent with the obtained tensile strength values. The bimodal behavior was reported by Zandsalimi et al [45] when investigating the dissimilar FSW of 430 stainless steel and 6061 aluminum alloy. These showed that this bimodal fracture occurs in the aluminum HAZ, which has the lowest hardness.…”

Section: Mechanical Propertiessupporting

confidence: 64%

Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties

Ahmed

Jouini

Alzahrani

et al. 2021

Metals

View full text Add to dashboard Cite

This study investigated the effect of the friction stir welding rotation rate and welding speed on the quality and properties of the dissimilar joints between aluminum and carbon steel. Plates of 4 mm thickness from both AA2024 and AISI 1018 were successfully friction stir butt welded at rotation speeds of 200, 250, and 300 rpm and welding speeds of 25, 50, and 75 mm/min. The joint quality was investigated along the top surface and the transverse cross-sections. Further investigation using scanning electron microscopy was conducted to assess the intermetallic layers and the grain refining in the stir zone. The mechanical properties were investigated using tensile testing for two samples for each weld that wire cut perpendicular to the welding direction and the hardness profiles were obtained along the transverse cross-section. Both the top surface and the transverse cross-section macrographs indicated defect free joints at a rotation rate of 250 rpm with the different welding speeds. The intermetallic compounds (IMCs) formation was significantly affected by the heat input, where there is no formation of IMCs at the Al/steel interfaces when higher traverse speed (75 mm/min) or lower rotation speed (200 rpm) were used, which gave the maximum tensile strength of about 230 MPa at the low rotation speed (200 rpm) along with 3.2% elongation. This is attributed to the low amount of heat input (22.32 J/mm) experienced. At the low traverse speed (25 mm/min and 250 rpm), a continuous layer of Al-rich IMCs FeAl3 is formed at the joint interface due to the high heat input experienced (79.5 J/mm). The formation of the IMCs facilitates fracture and reduced the tensile strength of the joint to about 98 MPa. The fracture mechanism was found to be of mixed mode and characterized by a cleavage pattern and dimples. The hardness profiles indicated a reduction in the hardness at the aluminum side and an increase at the steel side.

show abstract

Section: Mechanical Propertiessupporting

confidence: 64%

Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties

Ahmed

Jouini

Alzahrani

et al. 2021

Metals

View full text Add to dashboard Cite

show abstract

“…Sumit et al [66] reported that during FSP on aluminum, high heat inputs cause over plasticization and formation of groove defects. Zand Salimi [67] also indicated that grooves form during FSW of AA6061 and 430 stainless steel, because high input produces a plasticized material in the SZ which cannot be maintained by the tool shoulder. On the other hand, the grooves (type 2) form due to insufficient stirring.…”

Section: The Mechanism Of Groove Formationmentioning

confidence: 99%

Numerical and experimental investigation of defects formation during friction stir processing on AZ91

et al. 2021

View full text Add to dashboard Cite

The heat generated during friction stir processing greatly affects defects formation in the processed zone of workpieces. In this paper, numerical modeling of this process is performed to determine the influence of tool rotational and traverse speeds and hence their ratio on the thermal distribution attained during the process. The aim is to produce defect-free processed samples by selecting adequate tool speeds. The mechanisms of defects formation depending on the peak temperature are also investigated. Experiments to verify the simulation results were conducted with the same process parameters. Several traverse speeds of 20, 40, 60, and 80 mm/min and rotational speeds of 700, 1000, 1200, and 2000 rpm were used during modeling and conducting the experiments. From the numerical and experimental results, it was found that; the high-speed processing conditions (low-generated heat) can produce defects such as tunnels and grooves, and the low-speed processing conditions (high-generated heat) can cause defects such as flashes. The experimental results show that during friction stir processing with the rotational speed of 1200 rpm and the traverse speed of 60 mm/min (speed ratio of 20), no macro defects in the processed zone were observed. According to the numerical results, the peak temperature during friction stir processing with these speeds was 475 °C. At this temperature, the material softened, the structure finely equiaxed and no large scale melting zone appeared in the processed zone. The developed model can be useful to investigate the occurrence of defects associated with different tool rotational and traverse speeds. Graphic abstract

show abstract

“…A common ground to these studies is that the excessive heat input and temperature in welds caused by high rotational speed and low welding speed favor the formation of thick IMC layers. This is because the tool causes high friction with the workpiece per unit time, thereby increasing temperature and hence the number of IMCs [46]. Wan et al [13] investigated the effect of rotational speed and welding speed on microstructure and mechanical properties of FSW joints between AA6082-T6 and Q235A steel.…”

Section: Rotational Speedmentioning

confidence: 99%

“…Upon applying pressure by tool shoulder, plasticized materials tend to come out of the weld seam like flash, leaving behind a groove on top of the weld surface. Zandsalimi et al [46] found that, in FSW of AA6061 and 430 stainless steel, tool shoulder was not able to contain the plasticized material inside the weld seam, as too high heat input was involved (rotational speed of 900 rpm and welding speed of 40 mm/min). As a result, macroscopic flash and grooves appeared on the weld surface, as displayed in Figure 20.…”

Section: Surface Grooves and Flash Generationmentioning

confidence: 99%

See 1 more Smart Citation

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Safeen

Spena

2019

Metals

View full text Add to dashboard Cite

Joining of aluminum alloys through friction stir welding (FSW) is effectively employed in several industries (e.g., aeronautics and aerospace) since it guarantees proper weld strength as compared to other joining technologies. Contrarily, dissimilar FSW of aluminum alloys and steels often poses important issues in the selection of welding parameters due to the difficulty to join different materials. Improper welding parameters give rise to the formation of intermetallic compounds, and internal and external defects (e.g., tunnel formation, voids, surface grooves, and flash). Intermetallic compounds are brittle precipitates of Al/Fe, which chiefly initiate crack nucleation, whereas internal and external defects mainly act as stress concentration factors. All these features significantly reduce joint strength under static and dynamic loading conditions. With reference to the literature, the influence of main welding parameters (rotational speed, welding speed, tool geometry, tilt angle, offset distance, and plunge depth) on the formation of intermetallic compounds and defects in FSW of aluminum alloys and steels is discussed here. Possible countermeasures to avoid or limit the above-mentioned issues are also summarily reported.

show abstract

Dissimilar friction-stir welding of 430 stainless steel and 6061 aluminum alloy: Microstructure and mechanical properties of the joints

Cited by 27 publications

References 26 publications

Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties

Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties

Numerical and experimental investigation of defects formation during friction stir processing on AZ91

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Contact Info

Product

Resources

About