Skip to main content
SpringerLink
Log in

Investigations on the effect of friction crush welding parameters in joining 6061 aluminium alloy to 304 stainless steel

  • Original Article
  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

Solid state welding processes are one of the growing principal technologies used to join similar and dissimilar materials. Friction crush welding (FCW) is a recently developed solid state welding process to overcome the difficulties in fusion welding of thin sheet metal workpieces. In this communication, dissimilar aluminium and stainless steel (Al − SS) welds prepared by FCW technique at different levels of process parameters, i.e., feed rate (15, 30, 45 mm/min) and tool rotation (2000, 3000, 4000 rpm) are investigated in terms of mechanical properties and micro-structural features. Tensile test investigation along with microscopic study gives the optimum welding conditions. Optical inverted microscopic study shows that deformation of material increases with increase in feed rate and tool rotation. Energy dispersive spectroscope (EDS) indicates the formation of intermetallic compounds, i.e., FeAl2, FeAl3 and Fe2Al5 in the weld zone. The successful demonstration of joining Al − SS dissimilar materials justifies the potential of FCW process.

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. K. Mori, N. Bay, L. Fratini, F. Micari and A. E. Tekkaya, Joining by plastic deformation, CIRP Ann.-Manuf. Techn., 62(2) (2013) 673–694.

    Article  Google Scholar 

  2. P. Cavaliere, R. Nobile, F. W. Panella and A. Squillace, Mechanical and microstructural behaviour of 2024–7075 aluminium alloy sheets joined by friction stir welding, Int. J. Mach. Tool Manuf., 46(6) (2006) 588–594.

    Article  Google Scholar 

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

    Article  Google Scholar 

  4. T. Nishida, T. Ogura, H. Nishida, M. Fujimoto, M. Takahashi and A. Hirose, Formation of interfacial microstructure in a friction stir welded lap joint between aluminium alloy and stainless steel, Sci. Technol. Weld Joi., 19(7) (2014) 609–616.

    Article  Google Scholar 

  5. M. S. Senthil, H. A. Noorul and P. Sathiya, Effect of welding parameters on the microstructure and mechanical properties of the friction-welded dissimilar joints of AA6063 alloy and faying surface-tapered AISI304L alloy, Weld World, 64 (2020) 483–499.

    Article  Google Scholar 

  6. E. Taban, J. E. Gould and J. C. Lippold, Dissimilar friction welding of 6061-T6 aluminum and AISI 1018 steel: properties and microstructural characterization, Mater. Design, 31(5) (2010) 2305–2311.

    Article  Google Scholar 

  7. G. Sharma and D. K. Dwivedi, Study on microstructure and mechanical properties of dissimilar steel joint developed using friction stir welding, Int. J. Adv. Manuf. Tech., 88 (2017) 1299–1307.

    Article  Google Scholar 

  8. Y. C. Chen, A. Gholinia and P. B. Prangnell, Interface structure and bonding in abrasion circle friction stir spot welding: a novel approach for rapid welding aluminium alloy to steel automotive sheet, Mater. Chem. Phys., 134(1) (2012) 459–463.

    Article  Google Scholar 

  9. T. Wang, H. Sidhar, R. S. Mishra, Y. Hovanski, P. Upadhyay and B. Carlson, Friction stir scribe welding technique for dissimilar joining of aluminium and galvanized steel, Sci. Technol. Weld Joi., 23(3) (2018) 249–255.

    Article  Google Scholar 

  10. R. Palanivel, P. K. Mathews, I. Dinaharan and N. Murugan, Mechanical and metallurgical properties of dissimilar friction stir welded AA5083-H111 and AA6351-T6 aluminum alloys, Trans. Nonferrous Met. Soc. China, 24(1) (2014) 58–65.

    Article  Google Scholar 

  11. A. Astarita, M. Coppola, S. Esposito, M. Liberini, I. Papa, F. Scherillo and A. Squillace, Experimental characterization of Ti6Al4V T joints welded through linear friction welding technique: microstructure and NDE, Adv. Manuf., 4 (2016) 305–313.

    Article  Google Scholar 

  12. M. W. Safeen, P. R. Spena, G. Buffa, D. Campanella, A. Masnata and L. Fratini, Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications, Adv. Manuf., 8 (2020) 59–71.

    Article  Google Scholar 

  13. M. Pourali, A. Abdollah-zadeh, T. Saeid and F. Kargar, Influence of welding parameters on intermetallic compounds formation in dissimilar steel/aluminum friction stir welds, J. Alloy Compd., 715 (2017) 1–8.

    Article  Google Scholar 

  14. T. Ogura, T. Nishida, Y. Tanaka, H. Nishida, S. Yoshikawa, M. Fujimoto and A. Hirose, Micro scale evaluation of mechanical properties of friction stir welded A6061 aluminium alloy/304 stainless steel dissimilar lap joint, Sci. Technol. Weld Joi., 18(2) (2013) 108–113.

    Article  Google Scholar 

  15. F. A. Besler, P. Schindele, R. J. Grant and M. J. R. Stegmuller, Friction crush welding of aluminium, copper and steel sheetmetals with flanged edges, J. Mater. Process. Tech., 234 (2016) 72–83.

    Article  Google Scholar 

  16. F. A. Besler, R. J. Grant, P. Schindele and M. J. R. Stegmuller, Advanced process possibilities in friction crush welding of aluminum, steel, and copper by using an additional wire, Metal. Mater. Trans. B, 48 (2017) 2930–2948.

    Article  Google Scholar 

  17. P. Singh, D. Deepak and G. S. Brar, Comparative evaluation of aluminum and stainless steel dissimilar welded joints, Mater. Today: Proc., 33(3) (2020) 1488–1492.

    Google Scholar 

  18. M. E. Abdullah, H. T. Elmetwally, N. G. Yakoub, M. N. El-sheikh and A. A. Abd-Eltwab, Effect of orbital friction crush welding parameters on aluminum tubes, Int. J. Sci. Tech. Res., 9(2) (2020) 4483–4486.

    Google Scholar 

  19. P. Singh, D. Deepak and G. S. Brar, Optimizing friction crush welding of two dissimilar metals — aluminium 6061 T-6 and stainless steel — AISI 304, ASME 15 th International Manufacturing Science and Engineering Conference (2020) V002T06A 009.

  20. P. Singh, D. Deepak and G. S. Brar, Optical micrograph and micro-hardness behavior of dissimilar welded joints of aluminum (Al 6061-T6) and stainless steel (SS 304) with friction crush welding, Mater. Today: Proc., 44(1) (2021) 1000–1004.

    Google Scholar 

  21. A. S. Jomah, F. A. Hashim and A. D. Subhi, Metallurgical investigation and mechanical properties of dissimilar friction crush welded Cu−Al sheets with flanged edge, IOP J. Phys.: Conf. Ser., 1973 (2021) 012116.

    Google Scholar 

  22. O. F. Sanchez-Femat, M. F. Delgado-Pamanes, L. A. Reyes-Osorio, M. A. Suarez-Rosales, J. F. Chavez-Alcala, R. Flores-Pinedo and J. D. Becerra-Marquez, Design and construction of an agglomeration friction welding machine, Weld Insp., 26 (2021) e2607.

    Google Scholar 

  23. A. Kumar and G. S. Brar, Numerical investigation of friction crush welding aluminium and copper sheet metals with flanged edges, E3S Web Conf. 2021, 309 (2021) 01015.

    Article  Google Scholar 

  24. R. P. Mahto, R. Kumar, S. K. Pal and S. K. Panda, A comprehensive study on force, temperature, mechanical properties and micro-structural characterizations in friction stir lap welding of dissimilar materials (AA6061-T6 & AISI304), J. Manuf. Process., 31 (2018) 624–639.

    Article  Google Scholar 

  25. H. Uzun, C. D. Donne, A. Argagnotto, T. Ghidini and C. Gambaro, Friction stir welding of dissimilar Al 6013-T4 to X5CrNi1810 stainless steel, Mater. Design, 26(1) (2005) 41–46.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical and Production Engineering, Guru Nanak Dev Engineering College, Ludhiana, Punjab, India

    Prem Singh

  2. Mechanical Engineering Department, Punjabi University, Patiala, Punjab, India

    Dharmpal Deepak

  3. Department of Mechanical Engineering, National Institute of Technology, Uttarakhand, Srinagar (Garhwal), Uttarakhand, India

    Gurinder Singh Brar

Authors
  1. Prem Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Dharmpal Deepak
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Gurinder Singh Brar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Gurinder Singh Brar.

Additional information

Prem Singh is an Assistant Professor of Mechanical Engineering at Guru Nanak Dev Engineering College, Ludhiana, Punjab, India. He received his Bachelor’s and Master’s from Guru Nanak Dev Engineering College Ludhiana and Punjab Agricultural University, Ludhiana, respectively. He is currently pursuing the Ph.D. at Punjabi University, Patiala, Punjab, India.

Dharmpal Deepak is an Assistant Professor of Mechanical Engineering at Punjabi University, Patiala, Punjab, India. He received his Master’s degree from GNDEC Ludhiana and his Ph.D. from UCoE, Punjabi University, Patiala. His main research fields are design of experiments, mechanics of composite materials and non-conventional machining.

Gurinder Singh Brar is an Associate Professor of Mechanical Engineering at NIT Uttarakhand, Srinagar (Garhwal), Uttarakhand, India. He received his Master’s degree from GNDEC Ludhiana and Ph.D. from UNCC, USA. His main research fields are welding, non-conventional machining and design.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Singh, P., Deepak, D. & Brar, G.S. Investigations on the effect of friction crush welding parameters in joining 6061 aluminium alloy to 304 stainless steel. J Mech Sci Technol 37, 1999–2008 (2023). https://doi.org/10.1007/s12206-023-0336-6

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-023-0336-6

Keywords

Search

Navigation