Simulation of weld morphology during friction stir welding of aluminum- stainless steel joint

Application of the hybrid process ultrasound enhanced friction stir welding on dissimilar aluminum/dual‐phase steel and aluminum/magnesium joints

“…For this group of hybrid joints the steel is always placed on the advancing side considering the aluminum as the softer base material which gets stirred onto the steel [9][10][11]. For the offset of the pin a shifting into the aluminum is common, whereas the pin touches the surface of the steel and thereby activates the interface for an improved bonding between aluminum and steel [9,12]. This interface is also characterized by the presence of an aluminum-rich continuous intermetallic phase consisting of Fe 2 Al 5 or FeAl 3 [13,14].…”

Friction Stir Welding for Marine Applications: Mechanical Behaviour and Microstructural Characteristics of Al-Mg-Si-Cu Plates

“…The FSW technology was developed using sophisticated robotic systems and software, facilitating the use of the FSW process in a wide range of industrial applications and working conditions (Mendes et al, 2016). Both experimental and numerical analysis are important for understanding the heat flow and the transfer between the steel tool and the workpiece during the FSW process, and the weld morphology (Chao et al, 2003;Fratini et al, 2006;Sadeghian, Taherizadeh and Atapour, 2018;Zhao et al, 2018). Authors Ku, Ha and Roh (2014) developed a mobile welding robot and software controls to be used for welding double hull structures in shipyards.…”

A review on friction-based joining of dissimilar aluminum–steel joints

“…Pin offset in Al leads to major plastic deformation of the Al material while partial deformation of the steel material, which causes the dispersion of steel particles and that consequently lead to mixing of steel particles into the Al matrix. 1,25,55,[69][70][71][72][73][74][75][76][77][78][79][80][81][82][83][84][85][86][87][88] The size of these steel particles are dependent on tool pin offset majorly as well as heat input given by the process parameters of rotational speed, travel speed, and tool design. Another important parameter is the position of the workpiece, 1,53,89,90 wherein, effective material flow and enhanced mixing can be obtained when steel is kept at the advancing side and Al at the retreating side.…”

“…The nonconsumable tool is having important elements such as pin diameter/dimensions, pin shape feature, shoulder diameter, shoulder surface geometry, shoulder to pin diameter ratio, and pin length that need to be fixed in such a way that effective dissimilar joint of Al-steel can be obtained. 3,55,[69][70][71][72][73][74][75][77][78][79][80][81]85, Shoulder diameter, its surface area, and shoulder to pin diameter ratio contribute maximum to the heat input that in turn influences joint formation. Pin dimensions and its features decide the material flow.…”