Enhancements on Dissimilar Friction Stir Welding Between AZ31 and SPHC Mild Steel With Al–Mg as Powder Additives

Abstract

Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

Friction stir alloying of AZ61 and mild steel with Al-CNT additive

“…The lowering in strength is probably was due to agglomerated CNT, which had an adverse effect on joint strength. The Al additive assisted in maintaining the aluminium composition in the alloy and promotes IMC formation, which is an essential part of joint formation leading to improved strength compared to without any additive specimen [5].

Figure 3 Joining strength for different welding speeds and additives.

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“…Insert filler materials as second phase reinforcement additives used for miscible and immiscible materials welding have received much attention. Many researchers used additives during FSW to study material flow or enhance joint mechanical characteristics [4,5]. Friction stir alloying (FSA), which is based on the concepts of friction stir welding, has gained a lot of attraction as a surface modification and fabrication of alloyed joints [6][7][8].…”

Modeling, Optimization and Performance Evaluation of TiC/Graphite Reinforced Al 7075 Hybrid Composites Using Response Surface Methodology

“…The automotive industry is one of the most significant contributors to these issues. Around 1.2 billion motor vehicles are anticipated to be on the road, accounting for 75% of pollution, 27% of greenhouse gas emissions, and 756 L/year of gasoline consumption [ 1 , 2 , 3 , 4 ]. The level of pollution and fuel consumption can be lowered considerably by increasing the vehicle’s fuel economy.…”

“…The level of pollution and fuel consumption can be lowered considerably by increasing the vehicle’s fuel economy. One approach to enhance fuel efficiency is to make the vehicle lighter by utilizing lightweight materials like aluminum and aluminum-based hybrid composites [ 4 ]. Hence, the demand for performance aluminum composites capable of withstanding harsh engineering conditions is already rising exponentially.…”

“…In addition to these unique properties, the hardness behavior improvement of AMCs has drawn considerable interest in the automotive and aircraft industries. Recent studies have adopted various existing manufacturing techniques, such as friction stir processing [ 13 , 14 , 15 , 16 ], mechanical alloying [ 17 , 18 , 19 ], friction stir processing [ 4 ], stir casting [ 20 , 21 , 22 ], and powder metallurgy [ 23 , 24 , 25 , 26 ] to fabricate improved hardness and scratch-resistant AMCs. Interestingly, powder metallurgy (PM) has attracted increasing interest in producing AMCs due to its significant benefits, such as the uniform dispersion of reinforcement particles in the matrix and limited likelihood of forming interfacial phases owing to reduced processing temperature [ 27 ].…”