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Effect of Dwell Time on Joint Interface Microstructure and Strength of Dissimilar Friction Stir Spot-Welded Al-5083 and St-12 Alloy Sheets

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Abstract

Joining of Al-5083 alloy sheet to St-12 steel sheet was performed using a new friction stir spot welding (FSSW) technique in which the tool pin tip did not enter lower steel sheet. Effect of dwell time on the microstructure and mechanical properties of the joints was studied by various methods including microhardness measurements, shear test, stereo and light microscopy as well as scanning and transmission electron microscopy (SEM and TEM). Results indicated that compared to the conventional FSSW process, stronger joints can be achieved by this FSSW technique. Cross-sectional observation of the failed specimens indicated the occurrence of final fracture from the circumference of the tool pin where the Al sheet thickness was decreased as a result of the tool pin penetration. However, microhardness measurements introduced these fracture locations as the hardest regions of the Al part of welds. In addition to the Al3Fe and Al5Fe2 intermetallic compounds reported in the literature to form at the interface of dissimilar Al/steel joints, a third layer of AlFe intermetallic compound was also identified adjacent to the steel side of welds. Enhancement of the dwell time from 5 to 15 seconds increased the intermetallic layer thickness from ~1.7 to ~3 µm and resulted in the formation of harder stirred zone. This consequently increased the strength of the weld.

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Acknowledgments

The authors would like to thank CIME-EPFL for providing electron microscopy facilities as well as Dr. Oveisi from EPFL for their support in STEM analysis.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Sharif University of Technology, Azadi Ave., P.O. Box 11365-9466, Tehran, Iran

    Eskandar Fereiduni, Mojtaba Movahedi & Amir Hossein Kokabi

  2. Institute of Applied Laser, Photonics and Surface Technologies (ALPS), Bern University of Applied Sciences, Burgdorf, 3400, Switzerland

    Hossein Najafi

Authors
  1. Eskandar Fereiduni
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  2. Mojtaba Movahedi
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  3. Amir Hossein Kokabi
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  4. Hossein Najafi
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Correspondence to Mojtaba Movahedi.

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Manuscript submitted April 6, 2015.

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Fereiduni, E., Movahedi, M., Kokabi, A.H. et al. Effect of Dwell Time on Joint Interface Microstructure and Strength of Dissimilar Friction Stir Spot-Welded Al-5083 and St-12 Alloy Sheets. Metall Mater Trans A 48, 1744–1758 (2017). https://doi.org/10.1007/s11661-017-3971-7

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