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Hybrid joining of cast aluminum and steel by compound casting and friction stir welding

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Abstract

For structural components in the vehicle body, a trend can be observed where components such as suspension struts or side members in differential steel design are being replaced by an integral design made of cast aluminum. The advantages here are a reduction in the number of individual parts and weight savings. However, since the rest of the body is still made of steel, the integration of cast parts presents the challenge of joining these dissimilar materials in the body shop. Due to the different chemical and physical properties of cast aluminum and steel, cold hybrid joining technologies such as self-pierce riveting in combination with gluing are largely used for this purpose. However, these technologies are associated with higher cycle times and larger space requirements than conventional spot welding for steel joints. In order to meet these challenges and to optimize the integration of castings into steel bodies, this thesis is looking into the possibility of producing hybrid Al/steel assemblies in foundries where the attachment points to the body are made of steel. These can then be integrated in the body shop using conventional spot welding. To produce these Al/steel assemblies, a hybrid joining method consisting of compound casting and friction stir welding was developed and investigated with the aim of meeting both the mechanical requirements of the body and the production sequences of the foundry. In order to gain an understanding of the joining mechanisms, the processes were first investigated separately and then combined with the aim of obtaining an overall higher joint strength. To this end, a sample geometry and test setup were designed to produce compound samples with different specifications of the steel insert using the high pressure die casting process. In a subsequent process step, the compound casting area was friction stir welded to achieve the final joint strength. Characterization of the joint properties was carried out by tensile tests and damage patterns as well as via microstructure analyses.

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Authors and Affiliations

  1. BMW Group, Meisenstraße 29, 84030, Ergolding, Germany

    Mario Senff

  2. Chair of Metal Forming and Casting, Technical University of Munich, Walther-Meißner-Str. 4, 85748, Garching, Germany

    Wolfram Volk

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Senff, M., Volk, W. Hybrid joining of cast aluminum and steel by compound casting and friction stir welding. Prod. Eng. Res. Devel. 17, 521–534 (2023). https://doi.org/10.1007/s11740-023-01184-9

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