Friction Stir Welding of Dissimilar Materials Aluminum AL6061-T6 to Ultra Low Carbon Steel

Abstract

Abstract:In this study, the microstructure and strength properties of friction stir welded 6061-T6 aluminum alloy to ultra-low carbon steel have been investigated using different advancing speeds of 100, 200, and 400 mm·min −1 at constant rotation rate. Microstructure observations have been conducted by optical and scanning electron microscopy. The joint strength was evaluated on a tensile testing machine. The effect of advancing speed on the shear load of a joint has been found, as well as a relationship between microstructures and mechanical properties.

Mechanical Properties and Microstructure of Dissimilar Friction Stir Welding of Pure Aluminum to Low Carbon Steel

“…M. Habibnia et al [16] (AA5050 to 304SS) and Hamed et al [17] (AA50052 to AISI 304) mentioned that the FSW defects appeared when the tool offset to steel side was approximately high up to 1.6 to 2 mm. Hamed et al [17] and Zakaria et al [18] (AA6061-T6 to Low carbon steel) reported that the strength of the joint increased with increasing the traverse speed. Shuhuai et al [19] obtained the best strength at the formation of thin IMC at the interface (less than 1 μm).…”

“…To overcome these welding problems, it should weld this joint without melting. There are solid state welding processes which join similar or dissimilar metals without melting such as friction welding [9], ultrasonic joining [10], FSW [11][12][13][14][15][16][17][18][19][20][21][22]. FSW was invented and patented by The Welding Institute (TWI) in1991 [23].…”

“…The tool of the FSW consists of a shoulder which helps to force the plasticized metal and a pin to stir this metal from side to side to make a joint. Few studies were investigated the welding of aluminum to steel by FSW [11][12][13][14][15][16][17][18][19][20][21][22]. M. Dehghani et al [11] welded mild steel to AA3003-H18.…”

Effect of pin offset on the mechanical properties of friction stir welded AA 6013 aluminum alloy plates

“…This study was performed to identify the effect of pin offset phenomenon and welding parameters on the mechanical and microstructural properties of friction stir welded AA 6013-T6 aluminum plates. This study differs from the other studies in literature with the formation of double weld seams produced by a special technique, namely weld seam overlapping, on AA 6013 similar plates, thus attempting to provide useful findings in response to pin offset technique [14,[28][29][30][31][32][33]. The main objective of using pin offset technique in the joining process of AA 6013 aluminum alloy is to minimize the possibility of defect formation via weld seam overlapping.…”

Pin Diameter Effect on Microstructure and Mechanical Properties of Dissimilar Friction Stir Lap Welding Aluminum Alloy 6061-T6 to Dual Phase Steel

“…They have found that for: a D/d ratio of 2.6 a yields maximum tensile strength was obtained whereas a minimum tensile strength was found at D/d ratio 2.8. In our previous works [23,24], we have studied the effect of the rotation speed and speed advance on the microstructure and the mechanical properties of the friction stir welded 6061 aluminum to dual phase Steel. The objective of this present work is to focus on the pin diameter effect on mechanical properties and microstructural characteristics of the friction stir welded 6061 aluminum alloy to dual phase steel.…”