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

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 0.0...

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Published inMetals (Basel ) Vol. 12; no. 10; p. 1574
Main Authors Liu, Jun, Guo, Ruixiu, Gong, Peng, Yue, Yumei, Yu, Zhanxing, Zhang, Yewei
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.10.2022
Subjects
Alloys
Aluminum
Aluminum alloys
aluminum and steel dissimilar metals
Aluminum base alloys
Austenitic stainless steels
Composite structures
Design
Dissimilar material joining
Dissimilar materials
Dissimilar metals
Ductile fracture
Ductile-brittle transition
Foils
friction stir lap welding
Friction stir welding
interface characteristics
Interlayers
Intermetallic compounds
Lap welding
Mechanical properties
Metal sheets
Ni interlayer
Nickel
Occlusion
Plates, Aluminum
Shear strength
Shear tests
Specialty metals industry
Stainless steel
Steel alloys
tensile shear strength
Thickness
Welding
China
Beijing China
Japan
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Abstract 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.
AbstractList 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.
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 AlNi[sub.3] IMCs layer, hook structure and mechanical occlusion. The AlNi[sub.3] 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.
Audience Academic
Author Gong, Peng
Yue, Yumei
Zhang, Yewei
Liu, Jun
Guo, Ruixiu
Yu, Zhanxing
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CitedBy_id crossref_primary_10_1080_01694243_2023_2266210
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crossref_primary_10_1080_10426914_2024_2362641
crossref_primary_10_1016_j_ijfatigue_2023_108096
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Snippet The composite structure of aluminum and steel (Al/steel) dissimilar metals has been applied in manufacturing industries for lightweight products, and friction...
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SubjectTerms Alloys
Aluminum
Aluminum alloys
aluminum and steel dissimilar metals
Aluminum base alloys
Austenitic stainless steels
Composite structures
Design
Dissimilar material joining
Dissimilar materials
Dissimilar metals
Ductile fracture
Ductile-brittle transition
Foils
friction stir lap welding
Friction stir welding
interface characteristics
Interlayers
Intermetallic compounds
Lap welding
Mechanical properties
Metal sheets
Ni interlayer
Nickel
Occlusion
Plates, Aluminum
Shear strength
Shear tests
Specialty metals industry
Stainless steel
Steel alloys
tensile shear strength
Thickness
Welding
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Title Interface Characteristics and Mechanical Properties of 2024 Aluminum Alloy and 304 Stainless Steel Dissimilar Alloys FSLW Joint with Ni Interlayer
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