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Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer

  • Phase Transformations during Solid-phase Welding and Processing
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Abstract

A novel single pass friction stir dovetailing (FSD) method was developed to join thick-plate Al-8Zn-2Mg-1.8Cu alloy (AA7099) to Ni-Cr-Mo steel in a lap configuration through the use of an Al-1Mg-0.6Si-0.25Cu alloy (AA6061) butter layer that significantly reduces interfacial failures by inhibiting the formation of brittle Fe–Al intermetallic compounds (IMC). This study evaluates the strength and microstructural evolution of the aluminum/steel joint interface between single pass FSD of AA7099/AA6061(butter)/steel fabricated using three different FSD tool configurations (full thread, half smooth/half thread, no thread), of which the half smooth/half thread tool produced the strongest weld joint due to the absence of a Zn-rich IMC layer. The strength was tested using lap shear tensile testing, and the microstructure was examined using analytical electron microscopy. A discussion of the new FSD technique, joint configurations, and process parameters is provided along with joint microstructural analyses and mechanical performance.

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Acknowledgments

This work was supported by the U.S. Army Combat Capabilities Development Command Ground Vehicle Systems Center [Military Interdepartmental Purchase Requests 10834736, 11008837, 11079043]. Pacific Northwest National Laboratory (PNNL) is operated by Battelle Memorial Institute for the United States Department of Energy under contract DE-AC05-76RL01830. The authors would also like to thank PNNL staff Alan Schemer-Kohrn and Anthony Guzman for assisting in microstructural analysis and mechanical testing.

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Authors and Affiliations

  1. Energy and Environment Directorate, Pacific Northwest National Laboratory, 902 Battelle Blvd., Richland, WA, 99354, USA

    Matthew J. Olszta, Nicole R. Overman, Md Reza-E-Rabby, Timothy R. Roosendaal & Scott A. Whalen

  2. U.S. Army Combat Capability Development Center – Ground Vehicle Systems Center, 6501 E 11 Mile Road, Warren, MI, 48397, USA

    Martin McDonnell

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  1. Matthew J. Olszta
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  2. Nicole R. Overman
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  3. Md Reza-E-Rabby
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  4. Timothy R. Roosendaal
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  5. Martin McDonnell
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  6. Scott A. Whalen
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Correspondence to Matthew J. Olszta.

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Olszta, M.J., Overman, N.R., Reza-E-Rabby, M. et al. Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer. JOM 73, 2203–2211 (2021). https://doi.org/10.1007/s11837-021-04668-0

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  • DOI: https://doi.org/10.1007/s11837-021-04668-0

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