Friction Welding of Aluminium and Aluminium Alloys with Steel

Abstract

The paper presents our actual knowledge and experience in joining dissimilar materials with the use of friction welding method. The joints of aluminium and aluminium alloys with the different types of steel were studied. The structural effects occurring during the welding process were described. The mechanical properties using, for example, (i) microhardness measurements, (ii) tensile tests, (iii) bending tests, and (iv) shearing tests were determined. In order to obtain high-quality joints the influence of different configurations of the process such as (i) changing the geometry of bonding surface, (ii) using the interlayer, or (iii) heat treatment was analyzed. Finally, the issues related to the selection of optimal parameters of friction welding process were also investigated.

Joining of dissimilar materials

“…This layer certainly is of importance, but the joint strength can also be influenced by alloying by diffusion, mechanical mixing, and mechanical deformation of the base materials along the interface. The IMC layers achieved in friction welding are typically less than that for resistance spot welding though peak strengths are achieved with comparable IMC layer thicknesses in the range of 0.2-2.0 mm for Al-steel joints [10]. The Al-steel inertia welded samples from Taban et al [239] exhibited a maximum IMC layer of only 250 nm consisting of FeAl, which is accounted for by a combination of intimate contact and heavy deformation in the AA6061 overcoming the activation barrier for diffusion to preferentially form FeAl and the more common Fe 2 Al 5 .…”

“…Thus, what can be found in the literature is a body of work highlighting the expansion of friction welding via new alloy combinations or investigation of process parameter-microstructure-property relationship in order to effect either relative deformation or intermetallic formation. Ambroziak et al [10] embodies this in a review of Al-steel friction welding with a special focus on austenitic stainless steels and how bond strength can be affected by: (i) changing the geometry of the bond surface, (ii) using an interlayer to change the resulting intermetallic structure, or (iii) heat treatment.…”

Pengaruh Waktu dan Tekanan Gesek terhadap Kekuatan Tarik Sambungan Paduan Aluminium dan Baja Karbon pada Pengelasan Gesek Continuous Drive

“…Lapisan intermetallic yang bersifat getas ini, akan semakin banyak terbentuk di batas sambungan, pada suatu proses pengelasan gesek, dengan temperatur pada proses yang semakin tinggi, dan semakin lama panas itu diterapkan, dalam hal ini adalah durasi waktu gesek yang semakin besar [10]. Lapisan intermetallic yang bersifat getas ini, menurunkan kekuatan tarik sambungan [2].…”

“…Lapisan intermetallic yang bersifat getas ini, menurunkan kekuatan tarik sambungan [2]. Foramsi lapisan intermetallic yang semakin terbal, menyebabkan kegetasan sambungan meningkat [10]. Formasi intermetallic yang bersifat getas ini mulai terbentuk pada temperatur di bawa temperatur leleh aluminium dengan terdifusinya atom-atom aluminium pada Fe [11].…”

Microstructures and Mechanical Properties of Al/Fe and Cu/Fe Joints by Continuous Drive Friction Welding

“…But it is difficult to use the traditional fusion welding method because of the tremendous difference in mechanical and metallurgical properties between dissimilar materials [5]. Continuous drive friction welding (CDFW), as the most promising method to join dissimilar materials, is importantly demanded in the manufacture of a new generation of aircraft, rocket, and shipboard equipment because of the advantages such as high material savings and low production time [6][7][8].…”