Effects of processing parameters on the friction stir spot joining of Al5083-O aluminum alloy to DP590 steel
Two dissimilar materials, aluminum alloy Al5083-O and advanced high strength steel DP590, were successfully joined by using friction stir spot joining (FSSJ). Satisfactory joint strengths were obtained at a rotational speed of 300 rpm and a plunge depth of 0.7 mm. Resulting joints were welded without a non-welded zone. This may be attributed to the enhanced smooth material flow owing to sufficient stirring effect and tool down force between the upper Al5083-O side and the lower DP590 side. The maximum tensile shear strength was 6.5 kN, which was higher than the joint strength required by the conventional method of resistance spot welding. The main fracture mode was plug fracture in the tensile shear test of joints. An intermetallic compound (IMC) layer with <6 μm thickness was formed at the joint interface, which meets the allowance value of <10 μm for the dissimilar material Al-Fe joints. Thus, the use of FSSJ to weld the dissimilar materials Al5083-O and DP590 resulted in mechanically and metallurgically sound joints.
Keywordsfriction stir spot joining (FSSJ) dissimilar materials grain refinement mechanical properties scanning electron microscopy (SEM)
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