Elucidation of intermetallic compounds and mechanical properties of dissimilar friction stir lap welded 5052 Al alloy and DP590 steel

Geng, Peihao; Morimura, Masashi; Ma, Hong; Ma, Yunwu; Ma, Ninshu; Liu, Huihong; Aoki, Yasuhiro; Fujii, Hidetoshi; Qin, Guoliang

doi:10.1016/j.jallcom.2022.164381

Cited by 33 publications

(13 citation statements)

References 59 publications

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“…Dong et al [20] stated that there was no adverse effect on the joint quality when the thickness of the Fe-Al IMC layer was less than 2 µm. Geng et al [28] dissimilar friction stir lap welded the 5052 Al alloy and DP590 steel and stated that the Al-Fe IMCs layer thickness beyond 1.5 µm was harmful to the joint strength. Wang et al [29] performed FSLW of the high-strength interstitial free steel and Al-Mg-Si alloy with a 0.1 mm Ni interlayer found that the tensile-shear load of the lap joint with a 1.8 µm thick IMCs was enhanced compared with the joint without the introduction of the Ni interlayer.…”

Section: Atomic Diffusionmentioning

confidence: 99%

Interface Characteristics and Mechanical Properties of 2024 Aluminum Alloy and 304 Stainless Steel Dissimilar Alloys FSLW Joint with Ni Interlayer

Guo

Gong

et al. 2022

Metals

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The composite structure of aluminum and steel (Al/steel) dissimilar metals has been applied in manufacturing industries for lightweight products, and friction stir lap welding (FSLW) has advantages for the welding of these two metals. To further enhance the strength of the Al/steel FSLW joint, a 0.02 mm thick nickel (Ni) foil was chosen as the interlayer, and slight plunging depth of a tool pin into the lower steel sheet was designed, which can respectively change the intermetallic compounds (IMCs) type and produce small welding heat. Choosing dissimilar 2024 aluminum alloy and 304 stainless steel materials as the research subject, the characteristics of the lap interface and the mechanical properties of the joint were mainly discussed. The results showed that the lap interface between the upper aluminum and lower steel sheets was made up of an AlNi3 IMCs layer, hook structure and mechanical occlusion. The AlNi3 IMCs layer with 2 μm thickness was in a reasonable range positive to the joint strength. When the rotating speed of the stirring tool increased from 800 to 1200 rpm and the welding speed of 75 mm/min was constant, the hook structure and the mechanical occlusion were both enhanced, and the tensile shear strength of the joint was decreased. A maximum joint tensile shear strength of 217 MPa was obtained at 800 rpm, and the strength value was 47.2 percent of that of the 2024 aluminum alloy base material. The Al/steel joint with shear fracture mode presented a brittle–ductile mixed fracture.

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Section: Atomic Diffusionmentioning

confidence: 99%

Interface Characteristics and Mechanical Properties of 2024 Aluminum Alloy and 304 Stainless Steel Dissimilar Alloys FSLW Joint with Ni Interlayer

Guo

Gong

et al. 2022

Metals

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“…Therefore, the combination of steel and aluminum alloys, i.e., the technique for joining dissimilar materials, is being developed. Methods using resistance spot welding [1][2][3][4][5][6], FSSW [7], laser welding [8], and mechanical fastening [9] have been considered for joining dissimilar materials such as steel and aluminum alloys. However, from the viewpoints of productivity and cost, it is desired to realize joining of dissimilar materials of steel and aluminum alloys using resistance spot welding.…”

Section: Introductionmentioning

confidence: 99%

Dissimilar Joining of High-Strength Steel and Aluminum Alloy Using Resistance Spot Welding with Die- and Punch-Shaped Electrodes

Iyota,

Hamaguchi,

Koga

2023

The 15th International Aluminium Conference

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“…Successful joints were made of polymers such as Polyethylene (PE) [ 53 , 54 ], Polycarbonate (PC) [ 55 , 56 ], and Polymethyl Methacrylate (PMMA) [ 57 , 58 ]. Furthermore, the FSW process was utilized to join dissimilar metals [ 59 , 60 , 61 , 62 , 63 , 64 , 65 , 66 , 67 , 68 ], dissimilar polymers [ 69 , 70 , 71 ], and hybrid metal–polymer joints [ 72 , 73 , 74 , 75 , 76 , 77 , 78 , 79 , 80 , 81 , 82 , 83 , 84 , 85 , 86 , 87 , 88 ]. Therefore, the FSW process gained global recognition due to its potential in various applications in the automotive, aerospace, shipbuilding, and railway industries [ 89 ].…”

Section: Introductionmentioning

confidence: 99%

“…Several studies reported a high joint strength for dissimilar materials using the FSW technique. Geng et al achieved a joint strength of 75% of Al5052 when using the FSW process to join Al5052 to DP590 steel [ 63 ]. In a similar study, Saravana et al joined Al6061 to Ti-6Al-4V and produced a joint with a strength of 87% of Al6061 [ 67 ].…”

Section: Introductionmentioning

confidence: 99%

A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures

et al. 2022

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Metal–polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal–polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal–polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal–polymer joint quality that have been reported in the literature.

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Elucidation of intermetallic compounds and mechanical properties of dissimilar friction stir lap welded 5052 Al alloy and DP590 steel

Cited by 33 publications

References 59 publications

Interface Characteristics and Mechanical Properties of 2024 Aluminum Alloy and 304 Stainless Steel Dissimilar Alloys FSLW Joint with Ni Interlayer

Interface Characteristics and Mechanical Properties of 2024 Aluminum Alloy and 304 Stainless Steel Dissimilar Alloys FSLW Joint with Ni Interlayer

Dissimilar Joining of High-Strength Steel and Aluminum Alloy Using Resistance Spot Welding with Die- and Punch-Shaped Electrodes

A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures

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