Characterization of different Al-to-steel dissimilar welds using an innovative FSW-based process
- Simar A. ,
- Mena N.J. ,
- Jacques P.J. ,
- et al
- Simar A. ,
- Mena N.J. ,
- Jacques P.J. and
- van der Rest C.
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Description
A friction melt bonding process was employed to fabricate dissimilar lap joints between ultralow carbon (0.01%C, 0.14%Mn) or dual-phase DP600 (0.08%C, 1.51%Mn, 0.35%Cr, 0.06%Mo) steel grades and 1050, 2024 or 6061 aluminium alloys and the microstructure and mechanical properties of the joints were investigated. The process involved a flat cylindrical tool made from cemented tungsten carbide (WC, 6%Co) being pressed against a top sheet of steel. Welding was performed at a rotational speed of 2000 rpm and advancing speeds of 100-700 mm/min. Microstructures and intermetallic layer formation were observed by SEM and electron back scattered diffraction. Mechanical properties were characterised by hardness measurements and lap shear tests. Issues discussed include the dependence of intermetallic layer thickness on process parameters, grain refinement in the thermomechanically affected zone in ultra-low carbon steels and the presence of porosity in 2024 alloys at high advancing speed.
10th International Symposium, 20-22 May 2014, Session 9A: Techniques III, Paper 03
Subjects
- Friction welding
- Welding
- Process
- Friction stir welding
- Process conditions
- Ferrous
- Material
- Steels
- Dissimilar materials
- Aluminium and Al alloys
- Nonferrous
- 1xxx Al series
- 2xxx Al series
- 6xxx Al series
- Microstructure
- Mechanical properties
- Properties
- Hardness
- Strength
- Ultimate tensile strength
- Weld zone
- Weld
- Thermomechanically affected zone
- Grain
- Shear strength
- Defects
- Cavities
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