Ultrasound enhanced friction stir welding of aluminum and steel: Process and properties of EN AW 6061/DC04-Joints

Thomä, Marco; Wagner, Guntram; Straß, Benjamin; Wolter, Bernd; Benfer, S.; Fürbeth, W.

doi:10.1016/j.jmst.2017.10.022

Cited by 68 publications

(23 citation statements)

References 25 publications

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“…The DC04 joining partner thereby got mechanically activated and, according to the pulse-pause-ratio, partially softened by the power ultrasound so that a broader deformation as well as the increased tearing of steel particles can take place. This is in accordance with the literature for Al/St joints [28,31]. Furthermore, Tian et al could detect a similar but more pronounced effect of the ultrasound assistance transmitted via the tool for dissimilar Al/Cu joints [25].…”

Section: Light Microscopysupporting

confidence: 90%

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Analysis of the Oscillation Behavior of Hybrid Aluminum/Steel Joints Realized by Ultrasound Enhanced Friction Stir Welding

Thomä

Gester

Wagner

et al. 2020

Metals

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Friction stir welding (FSW) is an innovative solid-state joining process, which is suitable for joining dissimilar materials with strongly differing physical and chemical properties such as aluminum and steel. Where other joining methods such as fusion welding struggle to achieve appropriate joint strengths due to the excessive formation of brittle aluminum-rich intermetallic phases (IMP), FSW joints of aluminum and steel only show small layers of IMP, thus, sufficient tensile strengths in proximity to the maximum tensile strength of the weaker aluminum base material can be reached. With the aim to optimize the mechanical and microstructural properties of such dissimilar joints for widening the field for possible industrial applications, several hybrid friction stir welding methods have been developed which include an additional energy input, whereas the ultrasound enhancement (USE-FSW) is one of the most promising. The current work was carried out on AA6061/DC04 joints which were successfully friction stir welded with and without ultrasound support, in respect to the influence of varying the ultrasound transmission side. The functionality of the USE-FSW setup could be verified by multi point laser vibrometer measurements. Additionally, a higher proportion of transversal oscillation for the transmission of power ultrasound into aluminum could be detected using a scanning vibrometer. In comparison to the conventionally friction stir welded joints the ultrasound enhancement led to an avoidance of weld defects and an increase of the steel particle volume in the stir zone. The joint produced with power ultrasound transmission via aluminum resulted in a more uniform interface.

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Section: Light Microscopysupporting

confidence: 90%

“…This is another indicator for the minimized contact between the probe and the steel. The verification for the origin of the steel particles from the DC04 base metal was provided in earlier work [31]. The transition area from stir zone to thermomechanical-affected zone contains a small pore (black circle).…”

Section: Light Microscopymentioning

confidence: 99%

Analysis of the Oscillation Behavior of Hybrid Aluminum/Steel Joints Realized by Ultrasound Enhanced Friction Stir Welding

Thomä

Gester

Wagner

et al. 2020

Metals

Self Cite

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“…For such applications, welded and brazed joints are of interest, because they show good mechanical properties (high temperature strength and fatigue strength) and a higher corrosion resistance in comparison to adhesive joints [7]. The welding techniques like resistance spot welding [8], friction stir welding [9], arc weld-brazing [10] and laser weldbrazing [11] offer a great potential for aluminum alloy/steel joining. However, these processes are often limited to special part geometries and designs of the welded joints.…”

Section: Introductionmentioning

confidence: 99%

Influence of the Thickness of the Reaction Zone in Aluminum/Stainless Steel Brazed Joints on the Mechanical Properties

Fedorov

Uhlig

Wagner

2021

Metals

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The study deals with the characterization of the relationship between the microstructure of the reaction zone and the mechanical properties in the brazed joints of aluminum alloy 3003 and stainless steel AISI 304 in order to determine the influence of the intermetallic layers on the tensile shear strength of the joints. The joints were produced by induction brazing using an AlSi10 filler in an argon atmosphere at a temperature of 600 °C. Due to the local heat input into the liquid brazing filler during a short brazing time, a thin reaction zone is formed in the brazed joints (~1 µm), which ensures good mechanical properties of the joints. In order to observe the growth kinetics of the reaction zone in the brazed joints and to investigate the influence of the thickness of the reaction zone on the mechanical properties of the brazed joints, the joints were aged at temperatures of 200 °C and 500 °C for 6, 48 and 120 h. The results have shown that the thickness of this layer increases to a maximum of 2 µm depending on the duration of the thermal aging at a temperature of 200 °C. The results of the tensile shear strength tests have shown that the brazed joints with this thin layer ensure a high strength. The thermal aging at a temperature of 500 °C influences the growth of the reaction zone in the brazed joints significantly. The total thickness of the reaction zone increases to a maximum of 12 µm during the thermal aging. The results of the tensile shear tests of these joints have shown that the thermal aging at a higher temperature leads to a decrease of the tensile shear strength of the brazed joints to 67% due to the growth of the existing intermetallic layer and the formation of a new intermetallic layer in the reaction zone.

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“…The majority of papers on the subject mention such fragments without going into greater detail [25]. Several works point to the formation of intermetallic compounds (IMC) around steel particles [26], while others evaluate their effect on the response to corrosion of the joint [27], being that the increment in the number of fragments significantly increases the corrosion rate [23][24][25][26][27][28]. It should be noted that different strategies have been presented to investigate the flow of material during FSW, such as insertion of markers, three-dimensional analysis using X-ray tomography or X-ray radiography in situ, use of different materials, the use of plasticine, and applied freezing after the pin breaks [29].…”

Section: Introductionmentioning

confidence: 99%

Control of Steel Detachment and Metal Flow on Aluminum-Steel Friction Stir Welding of thin Joints

Graciano-Uribe

Santos

2021

IJE

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In the last thirty years, the friction stir welding (FSW) process has achieved significant importance due to the satisfactory results derived from severe deformation and low heat input during the welded joint production. These elements have been considered to implement the FSW in different welded systems, including aluminum-steel joints. In these dissimilar joints, the main interest was to obtain a welded joint with acceptable mechanical behavior. Some papers recently focused on understanding dissimilar joints process, mainly on the metal flow and its response to corrosion. However, in Al-steel joints, the presence of steel particles in the nugget zone is routine, it alters both the mechanical and chemical behavior of welded joints. Thus, this work aims to evaluate the mechanisms that govern these particles' generation, the effect of offset on their formation, and proposing the material flow behavior, using the detached fragments as tracers. It was established that the offset controls the metal's fluidity, which allows the accumulation of steel fragments on the advanced side, and reducing its quantity, due to the decrease of irregularities in the Al-steel interface. Likewise, the metal flow was observed on the retreating side, with that mentioned in aluminum joints. In contrast, on the advanced side, there is a shear action, push down, and lateral movement towards the retreating side, driven by the high forging strength of the metal and the restriction imposed by the steel and the backing.

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Ultrasound enhanced friction stir welding of aluminum and steel: Process and properties of EN AW 6061/DC04-Joints

Cited by 68 publications

References 25 publications

Analysis of the Oscillation Behavior of Hybrid Aluminum/Steel Joints Realized by Ultrasound Enhanced Friction Stir Welding

Analysis of the Oscillation Behavior of Hybrid Aluminum/Steel Joints Realized by Ultrasound Enhanced Friction Stir Welding

Influence of the Thickness of the Reaction Zone in Aluminum/Stainless Steel Brazed Joints on the Mechanical Properties

Control of Steel Detachment and Metal Flow on Aluminum-Steel Friction Stir Welding of thin Joints

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