Skip to main content
SpringerLink
Log in

Microstructural characteristics and mechanical properties of the dissimilar friction-stir butt welds between an Al–Mg alloy and A316L stainless steel

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this research, dissimilar butt joining of an Al–Mg alloy (AA5083) to austenitic stainless steel (A316L) by using friction-stir welding (FSW) process was examined. FSW parameters and joint design were optimized, owning to achieve the best joint strength. The processed FSWs at the optimized traverse speeds of 16, 20, and 25 mm/min with the sound surface appearance were considered for further cross-sectional investigations, microstructural characterizations, and mechanical testings. In situ reactions at the interface of Al–Mg alloy and stainless steel during FSW processes were studied by using field emission-scanning electron microscopy (FE-SEM) and line-scan energy-dispersive X-ray spectroscopy (EDS) analysis. As expected from the monitored thermal histories during FSW joining, the features indicating the formation of tunneling like defects were observed at low heat inputs (low w/v ratios). Moreover, some discontinuous thin intermetallic layers (with the thickness of ∼0.5 μm) were formed at the joint interface at the expressed processing conditions. Mechanical performances of the prepared dissimilar joints were assessed during transverse tensile loading and Vickers indentation micro-hardness testing. The joint strength ratio to the ultimate tensile strength (UTS) of the weakest base metal (BM) was improved up to ∼93 %, as all of the dissimilar FSWs failed from the Al–Mg base alloy, with a Vickers hardness enhancement of ∼460 % at the interface.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Abibe AB, Amancio-Filho ST, dos Santos JF, Hage E Jr (2013) Mechanical and failure behaviour of hybrid polymer–metal staked joints. Mater Des 46:338–347

    Article  Google Scholar 

  2. Amancio-Filho ST, Bueno C, dos Santos JF, Huber N, Hage E Jr (2011) On the feasibility of friction spot joining in magnesium/fiber-reinforced polymer composite hybrid structures. Mater Sci Eng A 528:3841–3848

    Article  Google Scholar 

  3. Bang H, Bang H, Jeon G, Oh I, Ro C (2012) Gas tungsten arc welding assisted hybrid friction stir welding of dissimilar materials Al6061-T6 aluminum alloy and STS304 stainless steel. Mater Des 37:48–55

    Article  Google Scholar 

  4. Hussein SA, Hadzley AS Characteristics of aluminum-to-steel joint made by friction stir welding: a review. Materials Today Commun 5:32–49

  5. Uzun H, Dalle Donne C, Argagnotto A, Ghidini T, Gambaro C (2005) Friction stir welding of dissimilar Al 6013-T4 to X5CrNi18-10 stainless steel. Mater Des 26:41–46

    Article  Google Scholar 

  6. Smith CB, Mishra RS (2014) Chapter 5 - examples of enhanced formability of high-strength aluminum alloys. In: Mishra CBSS (ed) Friction stir processing for enhanced low temperature formability. Butterworth-Heinemann, Boston, pp. 125–132

    Chapter  Google Scholar 

  7. Benedyk JC (2010) 3. Aluminum alloys for lightweight automotive structures. In: Mallick PK (ed) Materials, design and manufacturing for lightweight vehicles. Woodhead Publishing, pp. 79–113

  8. Starke EA Jr, Staley JT (1996) Application of modern aluminum alloys to aircraft. Prog Aerosp Sci 32:131–172

    Article  Google Scholar 

  9. Sharifitabar M, Sarani A, Khorshahian S, Shafiee AM (2011) Fabrication of 5052Al/Al2O3 nanoceramic particle reinforced composite via friction stir processing route. Mater Des 32:4164–4172

    Article  Google Scholar 

  10. Khodabakhshi F, Simchi A, Kokabi AH, Gerlich AP, Nosko M (2015) Effects of stored strain energy on restoration mechanisms and texture components in an aluminum–magnesium alloy prepared by friction stir processing. Mater Sci Eng A 642:204–214

    Article  Google Scholar 

  11. Khodabakhshi F, Kazeminezhad M (2011) The effect of constrained groove pressing on grain size, dislocation density and electrical resistivity of low carbon steel. Mater Des 32:3280–3286

    Article  Google Scholar 

  12. Lohwasser D, Chen Z (2009) Friction stir welding: from basics to applications. Elsevier

  13. Kundu S, Roy D, Bhola R, Bhattacharjee D, Mishra B, Chatterjee S (2013) Microstructure and tensile strength of friction stir welded joints between interstitial free steel and commercially pure aluminium. Mater Des 50:370–375

    Article  Google Scholar 

  14. Lee W-B, Schmuecker M, Mercardo UA, Biallas G, Jung S-B (2006) Interfacial reaction in steel–aluminum joints made by friction stir welding. Scr Mater 55:355–358

    Article  Google Scholar 

  15. Nishida H, Kurashima H, Fujimoto M, Nishikawa H, Ogura T, Hirose A (2013) Dissimilar lap joining of thick plates of A3003 aluminum alloy to SUS304 stainless steel by friction stir welding. In: Fujii H (ed) Proceedings of the 1st International Joint Symposium on Joining and Welding. Woodhead Publishing, pp. 237–241

  16. Ramachandran KK, Murugan N, Shashi KS (2015) Influence of tool traverse speed on the characteristics of dissimilar friction stir welded aluminium alloy, AA5052 and HSLA steel joints. Arch Civil Mech Eng 15:822–830

    Article  Google Scholar 

  17. Shen Z, Chen Y, Haghshenas M, Gerlich AP (2015) Role of welding parameters on interfacial bonding in dissimilar steel/aluminum friction stir welds. Eng Sci Technol Int J 18:270–277

    Article  Google Scholar 

  18. Movahedi M, Kokabi A, Reihani SS, Najafi H (2011) Mechanical and microstructural characterization of Al-5083/St-12 lap joints made by friction stir welding. Procedia Engineering 10:3297–3303

    Article  Google Scholar 

  19. van der Rest C, Jacques PJ, Simar A (2014) On the joining of steel and aluminium by means of a new friction melt bonding process. Scr Mater 77:25–28

    Article  Google Scholar 

  20. Chen CM, Kovacevic R (2004) Joining of Al 6061 alloy to AISI 1018 steel by combined effects of fusion and solid state welding. Int J Mach Tools Manuf 44:1205–1214

    Article  Google Scholar 

  21. Chen J, Li J, Shalchi Amirkhiz B, Liang J, Zhang R (2014) Formation of nanometer scale intermetallic phase at interface of aluminum-to-steel spot joint by welding–brazing process. Mater Lett 137:120–123

    Article  Google Scholar 

  22. Qin G, Lei Z, Su Y, Fu B, Meng X, Lin S (2014) Large spot laser assisted GMA brazing–fusion welding of aluminum alloy to galvanized steel. J Mater Process Technol 214:2684–2692

    Article  Google Scholar 

  23. G-l Q, Y-h S, Wang S-j (2014) Microstructures and properties of welded joint of aluminum alloy to galvanized steel by Nd:YAG laser + MIG arc hybrid brazing-fusion welding. Trans Nonferrous Metals Soc China 24:989–995

    Article  Google Scholar 

  24. Sierra G, Peyre P, Deschaux Beaume F, Stuart D, Fras G (2008) Galvanised steel to aluminium joining by laser and GTAW processes. Mater Charact 59:1705–1715

    Article  Google Scholar 

  25. Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R: Rep 50:1–78

    Article  Google Scholar 

  26. Nandan R, DebRoy T, Bhadeshia HKDH (2008) Recent advances in friction-stir welding – process, weldment structure and properties. Prog Mater Sci 53:980–1023

    Article  Google Scholar 

  27. Çam G, Mistikoglu S (2014) Recent developments in friction stir welding of Al-alloys. J Mater Eng Perform 23:1936–1953

    Article  Google Scholar 

  28. Sabooni S, Karimzadeh F, Enayati MH, Ngan AHW (2015) Friction-stir welding of ultrafine grained austenitic 304 L stainless steel produced by martensitic thermomechanical processing. Mater Des 76:130–140

    Article  Google Scholar 

  29. Wang D, Ni DR, Xiao BL, Ma ZY, Wang W, Yang K (2014) Microstructural evolution and mechanical properties of friction stir welded joint of Fe–Cr–Mn–Mo–N austenite stainless steel. Mater Des 64:355–359

    Article  Google Scholar 

  30. Dehghani M, Mousavi SAAA, Amadeh A (2013) Effects of welding parameters and tool geometry on properties of 3003-H18 aluminum alloy to mild steel friction stir weld. Trans Nonferrous Metals Soc China 23:1957–1965

    Article  Google Scholar 

  31. Haghshenas M, Abdel-Gwad A, Omran AM, Gökçe B, Sahraeinejad S, Gerlich AP (2014) Friction stir weld assisted diffusion bonding of 5754 aluminum alloy to coated high strength steels. Mater Des 55:442–449

    Article  Google Scholar 

  32. Liu X, Lan S, Ni J (2015) Electrically assisted friction stir welding for joining Al 6061 to TRIP 780 steel. J Mater Process Technol 219:112–123

    Article  Google Scholar 

  33. Khodabakhshi F, Haghshenas M, Sahraeinejad S, Chen J, Shalchi B, Li J et al (2014) Microstructure-property characterization of a friction-stir welded joint between AA5059 aluminum alloy and high density polyethylene. Mater Charact 98:73–82

    Article  Google Scholar 

  34. Coelho RS, Kostka A, dos Santos JF, Kaysser-Pyzalla A (2012) Friction-stir dissimilar welding of aluminium alloy to high strength steels: mechanical properties and their relation to microstructure. Mater Sci Eng A 556:175–183

    Article  Google Scholar 

  35. Dehghani M, Amadeh A, Akbari Mousavi SAA (2013) Investigations on the effects of friction stir welding parameters on intermetallic and defect formation in joining aluminum alloy to mild steel. Mater Des 49:433–441

    Article  Google Scholar 

  36. Imaizumi T, Morisada Y, Fujii H, Matsushita M, Ikeda R (2013) Three-dimensional visualization of material flow during friction stir welding for steel and aluminum by two pairs of X-ray transmission systems. In: Fujii H (ed) Proceedings of the 1st International Joint Symposium on Joining and Welding: Woodhead Publishing, pp. 359–361.

  37. Liu X, Lan S, Ni J (2014) Analysis of process parameters effects on friction stir welding of dissimilar aluminum alloy to advanced high strength steel. Mater Des 59:50–62

    Article  Google Scholar 

  38. Ogura T, Saito Y, Nishida T, Nishida H, Yoshida T, Omichi N et al (2012) Partitioning evaluation of mechanical properties and the interfacial microstructure in a friction stir welded aluminum alloy/stainless steel lap joint. Scr Mater 66:531–534

    Article  Google Scholar 

  39. Ramachandran KK, Murugan N, Shashi KS (2015) Effect of tool axis offset and geometry of tool pin profile on the characteristics of friction stir welded dissimilar joints of aluminum alloy AA5052 and HSLA steel. Mater Sci Eng A 639:219–233

    Article  Google Scholar 

  40. Tanaka T, Morishige T, Hirata T (2009) Comprehensive analysis of joint strength for dissimilar friction stir welds of mild steel to aluminum alloys. Scr Mater 61:756–759

    Article  Google Scholar 

  41. Watanabe T, Takayama H, Yanagisawa A (2006) Joining of aluminum alloy to steel by friction stir welding. J Mater Process Technol 178:342–349

    Article  Google Scholar 

  42. Piccini JM, Svoboda HG (2015) Effect of pin length on friction stir spot welding (FSSW) of dissimilar aluminum-steel joints. Procedia Mater Sci 9:504–513

    Article  Google Scholar 

  43. Springer H, Kostka A, dos Santos JF, Raabe D (2011) Influence of intermetallic phases and Kirkendall-porosity on the mechanical properties of joints between steel and aluminium alloys. Mater Sci Eng A 528:4630–4642

    Article  Google Scholar 

  44. Chen YC, Nakata K (2008) Effect of the surface state of steel on the microstructure and mechanical properties of dissimilar metal lap joints of aluminum and steel by friction stir welding. Metall and Mat Trans A. 39:1985–1992

    Article  Google Scholar 

  45. Taban E, Gould JE, Lippold JC (2010) Dissimilar friction welding of 6061-T6 aluminum and AISI 1018 steel: properties and microstructural characterization. Mater Des 31:2305–2311

    Article  Google Scholar 

  46. Ghosh M, Gupta RK, Husain MM (2014) Friction stir welding of stainless steel to Al alloy: effect of thermal condition on weld nugget microstructure. Metall and Mat Trans A 45:854–863

    Article  Google Scholar 

  47. Lee C-Y, Choi D-H, Yeon Y-M, Jung S-B (2009) Dissimilar friction stir spot welding of low carbon steel and Al–Mg alloy by formation of IMCs. Sci Technol Weld Join 14:216–220

    Article  Google Scholar 

  48. Belali-Owsia M, Bakhshi-Jooybari M, Hosseinipour SJ, Gorji AH (2015) A new process of forming metallic bipolar plates for PEM fuel cell with pin-type pattern. Int J Adv Manuf Technol 77:1281–1293

    Article  Google Scholar 

  49. Aval HJ, Serajzadeh S, Kokabi A (2011) Thermo-mechanical and microstructural issues in dissimilar friction stir welding of AA5086–AA6061. J Mater Sci 46:3258–3268

    Article  Google Scholar 

  50. He X, Gu F, Ball A (2014) A review of numerical analysis of friction stir welding. Prog Mater Sci 65:1–66

    Article  Google Scholar 

  51. Sun YF, Fujii H, Takaki N, Okitsu Y (2013) Microstructure and mechanical properties of dissimilar Al alloy/steel joints prepared by a flat spot friction stir welding technique. Mater Des 47:350–357

    Article  Google Scholar 

  52. McNelley TR, Swaminathan S, Su JQ (2008) Recrystallization mechanisms during friction stir welding/processing of aluminum alloys. Scr Mater 58:349–354

    Article  Google Scholar 

  53. Zhou F, Liao XZ, Zhu YT, Dallek S, Lavernia EJ (2003) Microstructural evolution during recovery and recrystallization of a nanocrystalline Al-Mg alloy prepared by cryogenic ball milling. Acta Mater 51:2777–2791

    Article  Google Scholar 

  54. Jata KV, Semiatin SL (2000) Continuous dynamic recrystallization during friction stir welding of high strength aluminum alloys. Scr Mater 43:743–749

    Article  Google Scholar 

  55. Sakai T, Belyakov A, Kaibyshev R, Miura H, Jonas JJ (2014) Dynamic and post-dynamic recrystallization under hot, cold and severe plastic deformation conditions. Prog Mater Sci 60:130–207

    Article  Google Scholar 

  56. Khodabakhshi F, Simchi A, Kokabi A, Nosko M, Švec P (2014) Strain rate sensitivity, work hardening, and fracture behavior of an Al-Mg TiO2 nanocomposite prepared by friction stir processing. Metall Mater Trans A 45:4073–4088

    Article  Google Scholar 

  57. Khodabakhshi F, Simchi A, Kokabi AH, Sadeghahmadi M, Gerlich AP (2015) Reactive friction stir processing of AA 5052–TiO2 nanocomposite: process–microstructure–mechanical characteristics. Mater Sci Technol 31:426–435

    Article  Google Scholar 

  58. Jeon J, Mironov S, Sato YS, Kokawa H, Park SHC, Hirano S (2011) Friction stir spot welding of single-crystal austenitic stainless steel. Acta Mater 59:7439–7449

    Article  Google Scholar 

  59. Mishra RS, Ma ZY, Charit I (2003) Friction stir processing: a novel technique for fabrication of surface composite. Mater Sci Eng A 341:307–310

    Article  Google Scholar 

  60. Mofid MA, Abdollah-zadeh A, Malek GF (2012) The effect of water cooling during dissimilar friction stir welding of Al alloy to Mg alloy. Mater Des 36:161–167

    Article  Google Scholar 

  61. Cram DG, Fang XY, Zurob HS, Bréchet YJM, Hutchinson CR (2012) The effect of solute on discontinuous dynamic recrystallization. Acta Mater 60:6390–6404

    Article  Google Scholar 

  62. Murr LE, Pizaña C (2007) Dynamic recrystallization: the dynamic deformation regime. Metall Mater Trans A 38(A):2611–2628

    Article  Google Scholar 

  63. Zhang Z, Wu Q (2015) Numerical studies of tool diameter on strain rates, temperature rises and grain sizes in friction stir welding. J Mech Sci Technol 29:4121–4128

    Article  Google Scholar 

  64. Zhang Z, Wu Q, Grujicic M, Wan ZY (2016) Monte Carlo simulation of grain growth and welding zones in friction stir welding of AA6082-T6. J Mater Sci 51:1882–1895

    Article  Google Scholar 

  65. Khodabakhshi F, Gerlich AP, Simchi A, Kokabi AH (2015) Cryogenic friction-stir processing of ultrafine-grained Al–Mg–TiO2 nanocomposites. Mater Sci Eng A 620:471–482

    Article  Google Scholar 

  66. Khodabakhshi F, Kazeminezhad M, Kokabi AH (2012) Resistance spot welding of ultra-fine grained steel sheets produced by constrained groove pressing: optimization and characterization. Mater Charact 69:71–83

    Article  Google Scholar 

  67. Zhang H, Lin SB, Wu L, Feng JC, Ma SL (2006) Defects formation procedure and mathematic model for defect free friction stir welding of magnesium alloy. Mater Des 27:805–809

    Article  Google Scholar 

  68. Zhang Z, Zhang HW (2014) Solid mechanics-based Eulerian model of friction stir welding. Int J Adv Manuf Technol 72:1647–1653

    Article  Google Scholar 

  69. Terasaki T, Akiyama T (2003) Mechanical behaviour of joints in FSW: residual stress, inherent strain and heat input generated by friction stir welding. Welding in the World 47:24–31

    Article  Google Scholar 

  70. Boyer HE, Gall TL (1985) Metals Handbook, Desk ed. ASMInternational, Metals Park

    Google Scholar 

  71. ASM handbook volume 2: properties and selection: nonferrous alloys and special-purpose materials

  72. Okano S, Mochizuki M, Toyoda M (2006) Thermal conductivity theoretical examination concerning characteristics of welding distortion produced by multiple heat sources - studies on welding distortion control by temperature distribution control using multiple heat sources (report 1). Quarterly Journal of the Japan Welding Society 24:324–330

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Materials Science and Engineering, School of Engineering, Shiraz University, Zand Boulevard, Shiraz, Iran

    R . Rafiei, A. Ostovari Moghaddam, M. R. Hatami & F. Khodabakhshi

  2. Advanced Materials and Nanotechnology Research Laboratory, Faculty of Materials Science and Engineering, K. N. Toosi University of Technology, Tehran, Iran

    A. Abdolahzadeh & A. Shokuhfar

Authors
  1. R . Rafiei
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. Ostovari Moghaddam
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. M. R. Hatami
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. F. Khodabakhshi
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. A. Abdolahzadeh
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. A. Shokuhfar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to F. Khodabakhshi.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rafiei, R..., Ostovari Moghaddam, A., Hatami, M.R. et al. Microstructural characteristics and mechanical properties of the dissimilar friction-stir butt welds between an Al–Mg alloy and A316L stainless steel. Int J Adv Manuf Technol 90, 2785–2801 (2017). https://doi.org/10.1007/s00170-016-9597-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-9597-x

Keywords

Search

Navigation