The authors applied friction stir welding in order to join an aluminum alloy containing magnesium to steel. In this study, the effects of pin rotation speed and pin offset toward the steel faying surface on the tensile strength and the structure of a joint were investigated. The following results were obtained: 1) Adjusting a rotating pin position to activate the faying surface of the steel enabled a joint to be produced between steel and an aluminum alloy. Welds were produced by placing the aluminum alloy on the retreating side of the joint. 2) There was an optimum rotation speed for the pin to make a sound joint. A lower rotation speed gave rise to an insufficient increase in temperature at the weld, so that the pin wore out in a short time. At a higher rotation speed, the temperature increase was so excessive that the magnesium in the Al alloy oxidized and resulted in an unsound joint. 3) The maximum tensile strength of the joint was obtained at the pin offset of 0.2 mm toward steel. At a larger offset, steel pieces scattering in the aluminum alloy matrix became larger in size and some voids were formed, resulting in a decrease in joint tensile strength. 4) Intermetallic compounds were not observed at the interface between the steel and the aluminum alloy. However, some intermetallic compounds were observed at the upper region of the weld where the temperature was higher due to the additional heat generated by the rotating tool shoulder. The intermetallic compounds formed at the upper region of the Fe/Al interface deteriorated the joint strength. 5) A minimum pin size was required to produce a weld. Pins that were too small in diameter, i.e., 1 mm diameter, could not produce a weld. Pin diameters from 2 to 4 mm showed similar joint tensile strength. 6) Welds could not be produced when the pin was rotated counterclockwise, i.e., the aluminum plate was mounted on the advancing side.
Friction stir welding of aluminum alloy to steel
Welding Journal, New York ; 83 , 10 ; 277S-282S
2004
6 Seiten, 16 Bilder, 10 Quellen
Aufsatz (Zeitschrift)
Englisch
Joining of aluminum alloy to steel by friction stir welding
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