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Hook formation and joint strength in friction stir spot welding of Al alloy and Al–Si-coated hot-press forming steel

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Abstract

In the automotive industry, the demand for ultra-high-strength steel is increasing due to the CO2 emission and safety regulations. Hot-press forming (HPF) steels are a type of boron-alloyed high-strength steel fabricated via hot-press forming, which enables both high strength and elongation. Because HPF is conducted at high temperatures (900–950 °C) for a few minutes, its surface is coated with Al–Si or Zn to prevent surface oxidation and decarburizing. However, the coating layer often influences the properties of the welds. In this study, friction stir spot welding (FSSW) is used to weld dissimilar metals, i.e., an Al alloy and Al–Si-coated HPF steel. The effects of Al–Si coating on the mechanical and metallurgical properties of the hook formation on the weld are investigated. The shape of the hook, which is formed during FSSW, changes from bent to straight shape due to the presence of Al–Si and the HPF process. The joint strength of the straight hook-shaped specimens is demonstrated to be lower than that of the bent hook-shaped specimens. This difference in strength is because the hard Fe–Al–Si intermetallic (IMC) layer on the outer surface of the hook disturbs the bending of the hook during the welding. On the outer surface of the hook, a Fe–Al–Si IMC layer of chemical composition similar to that of the coating layer formed during HPF is observed. This formation is different from the inner surface of the hook, wherein a thin Fe–Al IMC layer is reconstructed between aluminum and steel. Thus, the hard Fe–Al–Si intermetallic layer transformed during the HPF process is the primary cause of the straight hook shape.

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Funding

This research was supported by a grant from the Ministry of Trade, Industry and Energy, Republic of Korea.

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Authors and Affiliations

  1. Joining Research Group, Korea Institute of Industrial Technology, Incheon, 21999, Korea

    Minjung Kang, Jinyoung Yoon & Cheolhee Kim

  2. School of Mechanical Engineering, Hanyang University, Seoul, 04763, Korea

    Jinyoung Yoon

  3. Department of Mechanical and Materials Engineering, Portland State University, Portland, OR, 97201, USA

    Cheolhee Kim

Authors
  1. Minjung Kang
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  2. Jinyoung Yoon
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  3. Cheolhee Kim
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Correspondence to Cheolhee Kim.

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Kang, M., Yoon, J. & Kim, C. Hook formation and joint strength in friction stir spot welding of Al alloy and Al–Si-coated hot-press forming steel. Int J Adv Manuf Technol 106, 1671–1681 (2020). https://doi.org/10.1007/s00170-019-04716-9

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  • DOI: https://doi.org/10.1007/s00170-019-04716-9

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