Investigation on lap-joint friction stir welding between AA6351 alloys and DP800 steel sheets

Abstract

With continuous growth and stringent demand for weight reduction in automotive structures, the automotive industry has shown an increasing interest in dissimilar aluminium-steel welding. Dissimilar lap joint between AA6351 alloys of 2 mm thickness and DP800 advanced high-strength dual-phase steel of 1 mm thickness has been attempted and joined successfully by friction stir welding with different combinations of parameters. The experimental results of this research work clearly indicate that joining of advanced highstrength steel and aluminium in lap-joint configuration is quite feasible with friction stir welding. Microstructural characterization has been performed by X-ray diffraction (XRD) technique and scanning electron microscopy (SEM). An intermetallic compounds layer was found in the interface of steel and aluminium with thickness of less than 7 lm and it was identified as Al 2 Fe and Al 3 Fe by XRD method. Thermal cycle has been measured and correlated with the microstructure. Shear tensile test has been performed for determining the maximum failure load for different combinations of parameters. Finally, mechanical properties and microstructural observation are correlated with each other.

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys

“…The maximum shear load of 7500N was achieved by Wan et al [10] when 6082-T6 aluminum and Q235A steel were friction stir lap welded with a tilt angle of 2.5° and resulted in defect-free weld. Various process parameters were used by Nguyen et al [11] to weld DP800 and AA6351 sheets, and they noticed that the weld joints with high intermetallic thickness had a higher joint strength.…”

“…It is evident from the abovementioned studies [1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17,18,19,20] that the selection of process parameters plays a significant role in determining the robustness of the weld. The objective of this study was to investigate the effect of tilt angle and pin depth on the welded joint.…”

An Experimental Study On Friction Stir Welding Of Aluminum-Magnesium Alloys For Improved Mechanical Properties Of Tailor Welded Blanks.

“…Some statistical process parameters were studied by few researchers and evidences were found in the open literature. The Taguchi method of optimization was utilized to optimize process parameters for Al-Mg-Si-Cu) alloys of the Aluminum 5000 and 6000 families for future automotive applications by researchers and researchers have focused on double friction stir welding technique and microstructure analysis at nugget zone [14,15,16,17]. During mechanical testing, Lee et al [18] produced a hybrid composite material from carbon reinforced polymers on CR 340 plates and discovered epoxy leaks and significant gaps.…”