Extrinsic-Riveting Friction Stir Lap Welding of Al/Steel Dissimilar Materials

To obtain high-quality joints of Al/steel dissimilar materials, a new extrinsic-riveting friction stir lap welding (ERFSLW) method was proposed combining the synthesis advantages of mechanical riveting and metallurgical bonding. SiC-reinforced Al matrix composite bars were placed in the prefabricate...

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Bibliographic Details
Published inMaterials Vol. 17; no. 8; p. 1830
Main Authors Meng, Xiangchen, Gao, Jiaze, Xie, Yuming, Huang, Tifang, Dong, Jihong, Ma, Xiaotian, Wang, Naijie, Huang, Yongxian
Format Journal Article
LanguageEnglish
Published Switzerland MDPI AG 16.04.2024
Subjects
Al/steel
Alloys
Aluminum base alloys
Aluminum matrix composites
Bonded joints
Dissimilar material joining
extrinsic-riveting friction stir lap welding
Friction stir welding
Intermetallic compounds
Lap welding
Mechanical joining
Mechanical properties
mechanical riveting
Metal sheets
metallurgical bonding
Plastic deformation
Riveted joints
Riveting
Rivets
Service life
Shear tests
Steel
Stress concentration
China
Japan
mechanical riveting
metallurgical bonding
extrinsic-riveting friction stir lap welding
Al/steel
mechanical properties
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Summary:To obtain high-quality joints of Al/steel dissimilar materials, a new extrinsic-riveting friction stir lap welding (ERFSLW) method was proposed combining the synthesis advantages of mechanical riveting and metallurgical bonding. SiC-reinforced Al matrix composite bars were placed in the prefabricated holes in Al sheets and steel sheets, arranged in a zigzag array. The bars were stirred and mixed with Al sheets under severe plastic deformation (SPD), forming composite rivets to strengthen the mechanical joining. SiC particles were uniformly dispersed in the lower part of the welding nugget zone (WNZ). The smooth transition between the SiC mixed zone and extrinsic-riveting zone (ERZ) ensured the metallurgical bonding. The maximum tensile shear load of the joints reached 7.8 kN and the maximum load of the weld per unit length was 497 N/mm. The fracture occurred at the interface between the rivets and steel sheets rather than the conventional Al/steel joining interface. Moreover, ERFSLW can prolong the service life of joints due to three fracture stages. This method can be further extended to the welding of other dissimilar materials that conform to the model of "soft/hard".
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ISSN:1996-1944
1996-1944
DOI:10.3390/ma17081830