TWI

Dissimilar lap joints between aluminium alloys and various steel grades were fabricated by friction stir welding (FSW), FSW tool wear was measured and a phenomenological law was developed with respect to pin length reduction over weld length to represent the tool wear rate. The material combinations comprised upper sheets of AA 6082-T6 (Al, 1.1%Mg, 0.96%Si, 0.41%Mn) or AA 5083-SPF (Al, 4.72%Mg, 0.87%Mn) aluminium alloys (thickness 1.6 or 1.7 mm, respectively) and bottom substrates of A1008 steel (0.03%C, 0.2%Mn, 0.02%Cr), DP800 galvanised steel (0.15%C, 1.8%Mn, 0.24%Cr, 0.03%Ni) and 201LN stainless steel (0.03%C, 6.98%Mn, 16.8%Cr, 4.55%Ni) with thicknesses of 2.2, 2 and 2.3 mm, respectively. FSW was performed with an MTS I-stir PDS system using a cylindrical tool made from WC, 25%Co cermet. The pin tool was characterised by microstructural analysis and temperature measurements. Tool wear was measured by 3D microtopography using a STIL system. FSW process windows and tool temperature analysis are discussed.

12th International Symposium, 26-28 Jun 2018, Session 4A: FSW Tools, Paper 01