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A prediction of Fe-Al IMC layer thickness in TIG-assisted hybrid friction stir welded Al/steel dissimilar joints by numerical analysis

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Abstract

In joining aluminum alloy to steel, excessive growth of Fe-Al intermetallics (IMC) can deteriorate the joint quality with its brittleness by low solubility of liquid aluminum in iron. This problem can be fixed by adopting a solid-state welding such as friction stir welding (FSW), but lack of plastic flow and excessive tool wear are limitations during the process. In this study, joining 2.5 mm thick Al5052 aluminum alloy to 1.4 mm thick DP590 high strength steel was proceeded by TIG-assisted hybrid friction stir welding (HFSW) to improve the plastic flow and to decrease plunging force on the FSW tool. The purpose of this study is to realize the effect of preheating source on the growth of IMC layer thickness based on the 3D heat transfer numerical model. Thermal characteristics and IMC layer thickness on the welded joints were estimated and validated with experimental results. Consequently, HFSW adopting 20 A TIG current achieved the highest average tensile strength as 184 MPa with 2.39 μm IMC layer thickness, and the numerical result showed a fair agreement to the experimental results. It is realized that the heat generation per unit length of the time significantly influences on the maximum temperature and the growth of IMC layer thickness.

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Abbreviations

k :

Thermal conductivity

ρ :

Density

C :

Specific heat

T :

Temperature

t :

Time variable

\( \dot{Q} \) :

Internal heat generation

\( \dot{Q_1} \) :

Heat generated by the tool shoulder at the tool shoulder-workpiece interface

η h :

Fraction of total generated heat transferred to the workpiece

η m :

Fraction of mechanical energy due to sticking friction converted to heat

P :

Axial force of FSW tool

r :

Radial distance from axis of the tool

δ :

Frictional sliding of friction along the shoulder-workpiece interface

μ f :

Coefficient of friction along the shoulder-workpiece interface

\( \dot{Q_2} \) :

Internal heat generation by the pin-workpiece interface

V :

Volume of presumed shear layer adjoining to the pin

A :

Total contact area of workpiece surrounding the pin to V

R :

Radial distance of the shear layer from the tool center

θ :

Inclination of the radial vector with the welding direction

ω:

Rotational speeds of the tool

U :

Welding speeds of the tool

τ y :

Temperature-dependent shear yield strength of workpiece

σ y :

Yield strength of workpiece based on Von Mises yield criteria

\( \dot{Q_3} \) :

Heat input from TIG electrode

d :

Energy distribution coefficient

η :

Process efficiency

P W :

Arc power

r eff :

Effective radius of TIG arc on top surface of the workpiece

h 0 :

Heat transfer coefficient

X :

IMC layer growth

X n :

IMC layer thickness at diffusion time of tn corresponding interface temperature Tn

k 0 :

Exponential factor

q ∗ :

Activation energy for the IMC layer growth

R g :

Universal gas constant

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Acknowledgments

This study was supported by research fund from Chosun University, Korea.

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Authors and Affiliations

  1. Department of Welding and Joining Science Engineering, Chosun University, Gwangju, South Korea

    Hee-Seon Bang, Atanu Das & Han-Sur Bang

  2. Joining and Welding Research Institute, Osaka University, Osaka, Japan

    Seong Min Hong

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  1. Hee-Seon Bang
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Correspondence to Seong Min Hong.

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Bang, HS., Hong, S.M., Das, A. et al. A prediction of Fe-Al IMC layer thickness in TIG-assisted hybrid friction stir welded Al/steel dissimilar joints by numerical analysis. Int J Adv Manuf Technol 106, 765–778 (2020). https://doi.org/10.1007/s00170-019-04560-x

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