On the Prediction of Hot Tearing in Al-to-Steel Welding by Friction Melt Bonding

Abstract

Aluminum alloy AA6061 was welded to dual-phase steel 980 (DP980) by the friction melt bonding (FMB) process. Hot tears have been suppressed by controlling the thermomechanical cycle. In particular, the welding speed and the thermal conductivity of the backing plate have been optimized. A finite-element thermomechanical model coupled with the Rappaz-Drezet-Gremaud (RDG) criterion has been used to explain these experimental observations. The hot tear susceptibility has been reduced with large thermal gradients and with the formation of a cellular microstructure. Both effects are favored by a backing plate made of a material with high thermal conductivity, such as copper.

Joining technology of steel and alluminum alloy sheets: State of the art

“…Šema elektrootpornog tačkastog zavarivanja elementima [25] Figure 1. Scheme of electric resistance element welding [25] Istraživanja na polju spajanja čelika i legura aluminijuma dominantna su i u pogledu primjene zavarivanja trenjem sa miješanjem (FSW) [26,27], tačkastog zavarivanja trenjem sa miješanjem (FSSW) [28] i zavarivanja trenjem sa miješanjem pomoću dodatnih elemenata (FEW) [29]. Zavarivanje trenjem sa miješanjem je postupak zavarivanja koji se izvodi pomoću specijalnog alata koji vrši zagrijavanje radnih komada i miješanje materijala dijelova koji se spajaju.…”

A new physical simulation tool to predict the interface of dissimilar aluminum to steel welds performed by friction melt bonding

“…Therefore, a significant number of experimental trials are required to determine the optimum FMB parameters resulting in high quality welds. There are two main factors controlling the quality of the weld: the IM bonding layer and the defects present in the weld [20,21]. The thickness, morphology and, thus, properties of the IM bonding layer are determined by the thermal and pressure cycles seen by the interface during the FMB process.…”