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Welding trials are reported to demonstrate joint formation between S45C mild steel and aluminium alloy 6063 using a friction stir diffusion process. Welding experiments were undertaken using a machining centre with a cemented carbide rotating tool, and process parameters (rotation speed, welding speed and tool offset) were optimised. Hardness and tensile strength measurements were undertaken. Cross-sectional microstructure was examined by optical microscopy and SEM, and elemental distribution was determined by energy dispersive x-ray analysis. The microstructure of the interface, HAZ and thermomechanically affected zone is discussed.

5th International Symposium, 14-16 Sep 2004, Session 7A: Steel, Paper 01