Abstract
With continuous growth and stringent demand for weight reduction in automotive structures, the automotive industry has shown an increasing interest in dissimilar aluminium–steel welding. Dissimilar lap joint between AA6351 alloys of 2 mm thickness and DP800 advanced high-strength dual-phase steel of 1 mm thickness has been attempted and joined successfully by friction stir welding with different combinations of parameters. The experimental results of this research work clearly indicate that joining of advanced high-strength steel and aluminium in lap-joint configuration is quite feasible with friction stir welding. Microstructural characterization has been performed by X-ray diffraction (XRD) technique and scanning electron microscopy (SEM). An intermetallic compounds layer was found in the interface of steel and aluminium with thickness of less than \(7 \,\upmu \hbox {m}\) and it was identified as \(\hbox {Al}_{2}\mathrm{Fe}\) and \(\hbox {Al}_{3}\mathrm{Fe}\) by XRD method. Thermal cycle has been measured and correlated with the microstructure. Shear tensile test has been performed for determining the maximum failure load for different combinations of parameters. Finally, mechanical properties and microstructural observation are correlated with each other.
Similar content being viewed by others
References
Das A, Shome M, Goecke S F and De A 2017 Joining of aluminium alloy and galvanized steel using a controlled gas metal arc process. J. Manuf. Process. 27: 179–187
Das A, Shome M, Das C R, Goecke S F and De A 2015 Joining of galvannealed steel and aluminium alloy using controlled short circuiting gas metal arc welding process. Sci. Technol. Weld. Join. 20(5): 402–408
Aritoshi M and Okita K 2002 Friction welding of dissimilar metals. J. Japan Weld. Soc. 71(6): 432–436
Thomas W M, Nicholas E D, Needham J C, Murch M G, Templesmith P and Dawes C J 1991 Improvements to friction welding. GB Patent Application No. 9125978.8
Chen C M and Kovacevic R 2004 Joining of Al 6061 alloy to AISI 1018 steel by combined effects of fusion and solid state welding. Int. J. Mach. Tool. Manuf. 44(11): 1205–1214
Lee W B, Schmuecker M, Mercardo U A, Biallas G and Jung S B 2006 Interfacial reaction in steel–aluminum joints made by friction stir welding. Scr. Mater. 55(4): 355–358
Fukumoto S, Tsubakino H, Okita K, Aritoshi M and Tomita T 2000 Amorphization by friction welding between 5052 aluminum alloy and 304 stainless steel. Scr. Mater. 42(8): 807–812
Uzun H, Donne C D, Argagnotto A, Ghidini T and Gambaro C 2005 Friction stir welding of dissimilar Al 6013-T4 to X5CrNi18-10 stainless steel. Mater. Des. 26(1): 41–46
Ylmaz M, Col M and Acet M 2002 Interface properties of aluminum–steel friction-welded components. Mater. Charact. 49(5): 421–429
Tanaka T, Morishige T and Hirata T 2009 Comprehensive analysis of joint strength for dissimilar friction stir welds of mild steel to aluminum alloys. Scr. Mater. 61(7): 756–759
Das H, Basak S, Das G and Pal T K 2013 Influence of energy induced from processing parameters on the mechanical properties of friction stir welded lap joint of aluminum to coated steel sheet. Int. J. Adv. Manuf. Technol. 64(9–12): 1653–1661
Movahedi M, Kokabi A H, Reihani S M S, Cheng M J and Wang C J 2013 Effect of annealing treatment on joint strength of aluminum–steel friction stir lap weld. Mater. Des. 44: 487–492
Elrefaey A, Takahashi M and Ikeuchi K 2005 Application of friction stir welding to lap joint of aluminum to steel. In: Proceedings of the National Meeting of JWS, p. 132
Kimapong K and Wanatabe T 2005 Lap joint of A5083 aluminum alloy and SS400 steel by friction stir welding. Mater. Trans. 46(4): 835–841
Chen Y C, Komazaki T, Kim Y G, Tsumura T and Nakata K 2007 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. In: Proceedings of the International Welding/Joining Conference, pp. 435–436
Chen Y C and 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. Mater Trans. A 39: 1985–1992
Kusuda Y 2013 Honda develops robotized FSW technology to weld steel and aluminum and applied it to a mass-production vehicle. Ind. Robot: Int. J. 40(3): 208–212
Haghshenas M, Abdel-Gwad A, Omran A M, Gökçe B, Sahraeinejad S and Gerlich A P 2014 Friction stir weld assisted diffusion bonding of 5754 aluminum alloy to coated high strength steels. Mater. Des. 55: 442–449
Sorger G, Wang H, Vilacal P and Santos T G 2017 FSW of aluminum AA5754 to steel DX54 with innovative overlap joint. Weld. World 61(2): 257–268
Campanell D, Spena P R, Buffa1 G and Fratini L 2016 Dissimilar Al–steel friction stir welding lap joints for automotive applications. In: Proceedings of the 19th International ESAFORM Conference on Material Forming, vol. 1769, pp. 100005-1–100005-6
Zheng Q, Feng X, Shen Y, Huang G and Zhao P 2016 Dissimilar friction stir welding of 6061 Al to 316 stainless steel using Zn as a filler metal. J. Alloys Compd. 686: 693–701
Leitao C, Arruti E, Aldanondo and E Rodrigues D M 2016 Aluminium–steel lap joining by multipass friction stir welding. Mater. Des. 106: 153–160
Zimmer S, Langlois L, Laye J and Bigot R 2010 Experimental investigation of the influence of the FSW plunge processing parameters on the maximum generated force and torque. Int. J. Adv. Manuf. Technol. 47(1–4): 2011–2015
Mehta M, Arora A, De A and Debroy T 2011 Tool geometry for friction stir welding—optimum shoulder diameter. Metall. Mater. Trans. A 42A(9): 2716–2722
Khandkar M Z H, Khan J A and Reynolds A P 2003 Prediction of temperature distribution and thermal history during friction stir welding: input torque based model. Sci. Technol. Weld. Join. 8(3): 165–174
Santella M, Grant G and Arbegast W 2003 Plunge testing to evaluate tool materials for friction stir welding of 6061+20 wt% Al\(_2{\rm O}_3\) composite. In: Proceedings of the 4th International Symposium on Friction Stir Welding
Acknowledgements
This research was supported by a project under Grant number B2018-SKH-05 and Center for Research and Applications in Science and Technology, Hung Yen University of Technology and Education, under Grant number UTEHY.T031.P1718.02.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Nguyen, V.N., Nguyen, Q.M., Thi, H.T.D. et al. Investigation on lap-joint friction stir welding between AA6351 alloys and DP800 steel sheets. Sādhanā 43, 160 (2018). https://doi.org/10.1007/s12046-018-0930-y
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s12046-018-0930-y