Skip to main content

Advertisement

SpringerLink
Log in

Microstructure characterization and mechanical properties of the continuous-drive axial friction welded aluminum/stainless steel joint

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

Abstract

Aluminum alloy and stainless steel were joined by a continuous-drive axial friction welding machine in this study. The effects of welding parameters on the morphology, microstructure, microhardness, tensile strength, and fracture surface of dissimilar joints were analyzed. The distribution, thickness, and composition of intermetallic compound (IMC) were also discussed. Results showed that the formation of flash only was on the aluminum side because 6061 Al underwent extensive deformation during welding. Al and Fe elements diffused at the bonding interface and formed the IMC layer. The IMC thickness near the 1/2 radius was the smallest, and the thinnest at the center region. With the increase of friction pressure, the tensile strength of joint first increased and then decreased. When forge pressure was below 220 MPa, joint strength was approximately linearly related to the forge pressure. Edge regions of joints had achieved metallurgical bonding. The central region was the weak joining, and the fracture surface contained some cracks, IMCs, and a small amount of dimples.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Reddy MG, Rao SA, Mohandas T (2008) Role of electroplated interlayer in continuous drive friction welding of AA6061 to AISI 304 dissimilar metals. Sci Technol Weld Join 13(7):619–628

    Article  Google Scholar 

  2. Karakizis PN, Pantelis DI, Dragatogiannis DA, Bougiouri VD, Charitidis CA (2019) Study of friction stir butt welding between thin plates of AA5754 and mild steel for automotive applications. Int J Adv Manuf Technol 102(9):3065–3076

    Article  Google Scholar 

  3. Huang Y, Huang T, Wan L, Meng X, Zhou L (2019) Material flow and mechanical properties of aluminum-to-steel self-riveting friction stir lap joints. J Mater Process Technol 263:129–137

    Article  Google Scholar 

  4. Bhamji I, Preuss M, Threadgill PL, Addison AC (2011) Solid state joining of metals by linear friction welding: a literature review. Mater Sci Technol 27(1):2–12

    Article  Google Scholar 

  5. Derazkola HA, Khodabakhshi F (2019) Underwater submerged dissimilar friction-stir welding of AA5083 aluminum alloy and A441 AISI steel. Int J Adv Manuf Technol 102(9):4383–4395

    Article  Google Scholar 

  6. Wan L, Huang Y (2018) Friction welding of AA6061 to AISI 316L steel: characteristic analysis and novel design equipment. Int J Adv Manuf Technol 95(9):4117–4128

    Article  Google Scholar 

  7. Wang T, Sidhar H, Mishra RS, Hovanski Y, Upadhyay P, Carlson B (2018) Friction stir scribe welding technique for dissimilar joining of aluminium and galvanised steel. Sci Technol Weld Join 23(3):249–255

    Article  Google Scholar 

  8. Ogawa D, Kakiuchi T, Hashiba K, Uematsu Y (2019) Residual stress measurement of Al/steel dissimilar friction stir weld. Sci Technol Weld Join:1–10

  9. Abioye TE, Mustar N, Zuhailawati H, Suhaina I (2019) Prediction of the tensile strength of aluminium alloy 5052-H32 fibre laser weldments using regression analysis. Int J Adv Manuf Technol 102(5):1951–1962

    Article  Google Scholar 

  10. Sahin M (2007) Evaluation of the joint-interface properties of austenitic-stainless steels (AISI 304) joined by friction welding. Mater Des 28(7):2244–2250

    Article  Google Scholar 

  11. Nicholas ED (2003) Friction processing technologies. Weld World 47(11):2–9

    Article  Google Scholar 

  12. Kimura M, Kusaka M, Kaizu K, Nakata K, Nagatsuka K (2016) Friction welding technique and joint properties of thin-walled pipe friction-welded joint between type 6063 aluminum alloy and AISI 304 austenitic stainless steel. Int J Adv Manuf Technol 82(1):489–499

    Article  Google Scholar 

  13. Maalekian M (2007) Friction welding – critical assessment of literature. Sci Technol Weld Join 12(8):738–759

    Article  Google Scholar 

  14. Luo J, Ye YH, Xu JJ, Luo JY, Chen SM, Wang XC, Liu KW (2009) A new mixed-integrated approach to control welded flashes forming process of damping-tube–gland in continuous drive friction welding. Mater Des 30(2):353–358

    Article  Google Scholar 

  15. Sahin M (2009) Characterization of properties in plastically deformed austenitic-stainless steels joined by friction welding. Mater Des 30(1):135–144

    Article  Google Scholar 

  16. Yılmaz M, Çöl M, Acet M (2003) Interface properties of aluminum/steel friction-welded components. Mater Charact 49(5):421–429

    Article  Google Scholar 

  17. Kimura M, Ishii H, Kusaka M, Kaizu K, Fuji A (2009) Joining phenomena and joint strength of friction welded joint between aluminium–magnesium alloy (AA5052) and low carbon steel. Sci Technol Weld Join 14(7):655–661

    Article  Google Scholar 

  18. James JA, Sudhish R (2016) Study on effect of interlayer in friction welding for dissimilar steels: SS 304 and AISI 1040. Procedia Technol 25:1191–1198

    Article  Google Scholar 

  19. Wang T, Sidhar H, Mishra RS, Hovanski Y, Upadhyay P, Carlson B (2019) Effect of hook characteristics on the fracture behaviour of dissimilar friction stir welded aluminium alloy and mild steel sheets. Sci Technol Weld Join 24(2):178–184

    Article  Google Scholar 

  20. Lee WB, Yeon YM, Kim DU, Jung SB (2003) Effect of friction welding parameters on mechanical and metallurgical properties of aluminium alloy 5052–A36 steel joint. Mater Sci Technol 19(6):773–778

    Article  Google Scholar 

  21. Kimura M, Suzuki K, Kusaka M, Kaizu K (2017) Effect of friction welding condition on joining phenomena, tensile strength, and bend ductility of friction welded joint between pure aluminium and AISI 304 stainless steel. J Manuf Process 25:116–125

    Article  Google Scholar 

  22. Kobayashi A, Machida M, Hukaya S, Suzuki M (2003) Friction welding characteristics of Al-Mg aluminum alloy (A5056) and carbon steel (S45C). JSME Int J 46(3):452–459

    Article  Google Scholar 

  23. Fukumoto S, Tsubakino H, Okita K, Aritoshi M, Tomita T (1999) Friction welding process of 5052 aluminium alloy to 304 stainless steel. Mater Sci Technol 15(9):1080–1086

    Article  Google Scholar 

  24. Kimura M, Kusaka M, Seo K, Fuji A (2005) Joining phenomena during friction stage of A7075-T6 aluminium alloy friction weld. Sci Technol Weld Join 10(3):378–383

    Article  Google Scholar 

  25. Chen X, Li L, Zhou D (2016) Review on the formation and inhibition mechanism of Fe-Al intermetallic compound (in Chinese). Int J Adv Manuf Technol 30(7):125–132

    Google Scholar 

  26. Lee J-M, Kang S-B, Sato T, Tezuka H, Kamio A (2003) Evolution of iron aluminide in Al/Fe in situ composites fabricated by plasma synthesis method. Mater Sci Eng A 362(1):257–263

    Article  Google Scholar 

  27. Huang Y, Wan L, Si X, Huang T, Meng X, Xie Y (2019) Achieving high-quality Al/steel joint with ultrastrong interface. Metall Mater Trans A 50(1):295–299

    Article  Google Scholar 

  28. 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 

  29. Reza-E-Rabby M, Ross K, Overman NR, Olszta MJ, McDonnell M, Whalen SA (2018) Joining thick section aluminum to steel with suppressed FeAl intermetallic formation via friction stir dovetailing. Scr Mater 148:63–67

    Article  Google Scholar 

  30. Kato K, Tokisue H (2004) Dissimilar friction welding of aluminium alloys to other materials. Weld Int 18(11):861–867

    Article  Google Scholar 

  31. Su H, Wu CS, Pittner A, Rethmeier M (2014) Thermal energy generation and distribution in friction stir welding of aluminum alloys. Energy 77:720–731

    Article  Google Scholar 

  32. Wan L, Huang Y (2018) Friction stir welding of dissimilar aluminum alloys and steels: a review. Int J Adv Manuf Technol 99(5):1781–1811

    Article  Google Scholar 

  33. Aghajani Derazkola H, Khodabakhshi F (2019) Intermetallic compounds (IMCs) formation during dissimilar friction-stir welding of AA5005 aluminum alloy to St-52 steel: numerical modeling and experimental study. Int J Adv Manuf Technol 100(9):2401–2422

    Article  Google Scholar 

  34. Huang Y, Xie Y, Meng X, Lv Z, Cao J (2018) Numerical design of high depth-to-width ratio friction stir welding. J Mater Process Technol 252:233–241

    Article  Google Scholar 

  35. Huang Y, Wan L, Meng X, Xie Y, Lv Z, Zhou L (2018) Probe shape design for eliminating the defects of friction stir lap welded dissimilar materials. J Manuf Process 35:420–427

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Materials Science and Engineering, Tsinghua University, Beijing, 100084, China

    Yong Liu & Haiyan Zhao

  2. China Iron & Steel Research Institute Group, Beijing, 100081, China

    Yong Liu & Yun Peng

  3. School of Materials Science and Engineering, Shandong University, Jinan, 250061, China

    Xiaofei Ma

Authors
  1. Yong Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Haiyan Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yun Peng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xiaofei Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Yong Liu, Haiyan Zhao or Yun Peng.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liu, Y., Zhao, H., Peng, Y. et al. Microstructure characterization and mechanical properties of the continuous-drive axial friction welded aluminum/stainless steel joint. Int J Adv Manuf Technol 104, 4399–4408 (2019). https://doi.org/10.1007/s00170-019-04245-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04245-5

Keywords

Search

Navigation