Microstructural evolution during friction stir welding of dissimilar aluminum alloy to advanced high-strength steel

Lan, Shuhuai; Liu, Xun; Ni, Jun

doi:10.1007/s00170-015-7531-2

Cited by 69 publications

(26 citation statements)

References 29 publications

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“…Hamed et al [17] and Zakaria et al [18] (AA6061-T6 to Low carbon steel) reported that the strength of the joint increased with increasing the traverse speed. Shuhuai et al [19] obtained the best strength at the formation of thin IMC at the interface (less than 1 μm). Masoumen et al [20], Long et al [21] and Z. shen [22] used a lap configuration to join aluminum to steel.…”

Section: Introductionmentioning

confidence: 99%

“…To overcome these welding problems, it should weld this joint without melting. There are solid state welding processes which join similar or dissimilar metals without melting such as friction welding [9], ultrasonic joining [10], FSW [11][12][13][14][15][16][17][18][19][20][21][22]. FSW was invented and patented by The Welding Institute (TWI) in1991 [23].…”

Section: Introductionmentioning

confidence: 99%

“…The tool of the FSW consists of a shoulder which helps to force the plasticized metal and a pin to stir this metal from side to side to make a joint. Few studies were investigated the welding of aluminum to steel by FSW [11][12][13][14][15][16][17][18][19][20][21][22]. M. Dehghani et al [11] welded mild steel to AA3003-H18.…”

Section: Introductionmentioning

confidence: 99%

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Mechanical Properties and Microstructure of Dissimilar Friction Stir Welding of Pure Aluminum to Low Carbon Steel

et al. 2018

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The purpose of this research is to use friction stir welding (FSW) to join dissimilar metals, annealed low carbon steel and A1050 pure aluminum. A butt joint with a similar sheet thickness of 1.9 mm was applied. The novelties of the research are relatively using high generated heat produced by a combination of low traverse speed and high rotational speed to perform the dissimilar joints and using a tool material (K107cold work tool steel) which has not been used in FSW with tool cooling. The present work studied the effect of FSW variables such as tilt angle, tool cooling, base metal location on mechanical properties. Tensile tests were used to evaluate the mechanical properties of the dissimilar joints. The microstructure specimens were examined using a scanning electron microscope (SEM). Sound dissimilar joints were successfully produced. The maximum joint efficiency obtained in this study is 51.7% of the aluminum tensile strength. The microstructure images showed that many steel fragments were sheared off from the steel surface by the tool action and scattered in the weld nugget, a continuous intermetallic compound (IMC) layer formed at the interface, the thickness of the IMC layer at the interface decreased in the thickness direction of the weld. FeAl3 IMC phase was only observed at the interface.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Mechanical Properties and Microstructure of Dissimilar Friction Stir Welding of Pure Aluminum to Low Carbon Steel

et al. 2018

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“…Some previous studies concerning this combination focused on the microstructure evolution [18,19] in different joining configurations. In butt joining configuration, some investigations dealt with the relation between mechanical strength and the existence of stainless steel particles in aluminum [20] or on IMC growth following the main process parameters [18]. Methods using the Taguchi technique extract the influence on the welding quality for each processing parameter [21].…”

Section: Introductionmentioning

confidence: 99%

A Correlation between the Ultimate Shear Stress and the Thickness Affected by Intermetallic Compounds in Friction Stir Welding of Dissimilar Aluminum Alloy–Stainless Steel Joints

Picot

Gueydan

Martinez

et al. 2018

Metals

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Abstract:In this work, Friction Stir Welding (FSW) was applied to join a stainless steel 316L and an aluminum alloy 5083. Ranges of rotation and translation speeds of the tool were used to obtain welding samples with different heat input coefficients. Depending on the process parameters, the heat generated by FSW creates thin layers of Al-rich InterMetallic Compound (IMC) mainly composed of FeAl 3 , identified by energy dispersive spectrometry. Traces of Fe 2 Al 5 were also depicted in some samples by X-ray diffraction analysis and transmission electron microscopy. Monotonous tensile tests performed on the weld joint show the existence of a maximum mechanical resistance for a judicious choice of rotation and translation speeds. It can be linked to an affected zone of average thickness of 15 µm which encompass the presence of IMC and the chaotic mixing caused by plastic deformation in this area. A thickness of less than 15 µm is not sufficient to ensure a good mechanical resistance of the joint. For a thickness higher than 15 µm, IMC layers become more brittle and less adhesive due to high residual stresses which induces numerous cracks after cooling. This leads to a progressive decrease of the ultimate shear stress supported by the bond.

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“…Highest joint strength obtained was 240 MPa, which is about 85% of the aluminium alloy. Analysis of the interface area detailed that thin layer of intermetallic compound (IMC) Fe 3 Al was created due to the reaction between sheared off steel particles and aluminum matrix, which was useful to produce a sound joint [15]. FSW butt joint of 3 mm thick aluminum alloy AA5052 and HSLA steel was done.…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Welding of Dissimilar Butt Joints with Novel Joint Geometry

Jayabalakrishnan¹,

Balasubramanian²

2018

Acta Phys. Pol. A

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In this study, 1 mm thin sheets of AA 6061 and steel were welded by friction stir, with new joint geometry. Conventional friction stir welding develops high distortion to the specimen, particularly when the thickness is very small. In this process, friction stir welding is carried out by a tool without probe and with new joint geometry. Contrary to the conventional friction stir welding, where various tool profiles are used to obtain successful joints, the present study of investigation focused on developing a profile in the sheet metal edges to be joined. The aluminium sheet was positioned on the contoured steel sheet. Rotating tool with tilt angle was made to progress into the top sheet. Frictional heat plasticized the upper blank and the edges of the aluminium sheet were forged and extruded into the steel contour. The welding between steel and aluminium was due to a coalescence of the two materials and clamping effect was provided by the contour in the steel sheet. Tensile test was conducted to evaluate the quality of the welding along with macro and micro metallographic investigations. Further to this, scanning electron microscopy with energy dispersive X-ray and X-ray diffraction analysis have been done to understand the presence of intermetallics at the weld nugget. Tensile strength of 122.22 MPa was achieved. Intermetallics of Mg2Si, MnAl6 and FeAl6, Al5Fe2 was found as dominant compound at the interface. Welding of thin sheets is enhanced by form clamping and chemical diffusion bonding.

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Microstructural evolution during friction stir welding of dissimilar aluminum alloy to advanced high-strength steel

Cited by 69 publications

References 29 publications

Mechanical Properties and Microstructure of Dissimilar Friction Stir Welding of Pure Aluminum to Low Carbon Steel

Mechanical Properties and Microstructure of Dissimilar Friction Stir Welding of Pure Aluminum to Low Carbon Steel

A Correlation between the Ultimate Shear Stress and the Thickness Affected by Intermetallic Compounds in Friction Stir Welding of Dissimilar Aluminum Alloy–Stainless Steel Joints

Friction Stir Welding of Dissimilar Butt Joints with Novel Joint Geometry

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