Abstract
Hybrid configurations between aluminium and steel are needed to meet today’s requirements for lightweight construction in the automotive industry. Different studies showed that Friction Stir Welding (FSW) as well as Friction Stir Spot Welding (FSSW) processes are suitable for joining aluminium to steel. In this work, dissimilar FSSW of aluminium AA5754 and galvanised steel HX 340LAD were examined. In particular the influence of different spindle speeds and dwell times on microstructure and the mechanical properties of the weld were analysed. In doing so, the cross-section microstructure of the weld interface was observed by light optical microscope (LOM) and scanning electron microscope (SEM). The strength of the welds was evaluated both by tensile shear and vibration fatigue tests. The influences of the individual parameters on the weld are presented in detail. The appearance of intermetallic phases (IMPs), a severe problem for conventional fusion welding processes between aluminium and steel, were investigated for the welded samples and a link to the mechanical properties is given.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Resch J.: Untersuchung zur Problematik der Metall-Schutzgassschweißung von Aluminium und Stahl (Construction of diffusion-layers MIG wire electrode welding of unalloyed steel and aluminium), MUL Leoben, 1994.
Zhang H.T., Feng J.C., He P., Hackl H.: Interfacial microstructure and mechanical properties of aluminiumzinc-coated steel joints made by a modified metal inert gas welding-brazing process, Materials Characterization, 2007, Vol. 58, 7, pp. 588–592.
Dupont J.N., Banovic S.W., Marder A.R.: Microstructural Evolution and Weldability of Dissimilar Weld between a Super Austenitic Stainless Steel and Nickel-Based Alloys, Welding Journal, June 2003, pp. 125-S-135-S.
Sato Y.S., Nelson T. W., Sterling C.J., Steel R. J., Pettersson C.O.: Microstructure and mechanical properties of friction stir welded SAF 2507 super duplex stainless steel, Materials Science & Engineering. A, 2005, Vol. 397, No. 1–2, pp. 376–384.
Uzun H. Dalle Donne C., Argagnotto A., Ghidini T., Gambaro C.: Friction stir welding of dissimilar AI 6013-T4 To X5CrNi18–10 stainless steel, Materials & Design, 2005, Vol. 26, No. 1, pp. 41–46.
Bozzi S. et al.: Influence of the dwell time on spot welding between 6008 AI alloy and steel by FSW in Proceedings of the Sixth International Friction Stir Welding Symposium, 2006, Saint Sauveur.
Binary alloy phase diagrams, ASM Handbook, Vol. 03, 1992, Materials Information Society.
Meyer L., Bühler H.-E.: Aufbau von Diffusionsschichten zwischen unlegiertem Stahl und Aluminium (Construction of diffusion-layers of unalloyed steel and aluminium), Aluminium 1967, vol. 12, pp. 733–738.
Naoi D., Kajihara M.: Growth behavior of Fe2AI5 during reactive diffusion between Fe and AI at solid-state temperatures, Materials Science & Engineering: A, 2007, Vol. 459, No. 1–2, pp. 375–382.
Sundaresan S., Murti K.G.K.: The formation of intermetallic phases in aluminium-austenitic stainless steel friction welds, Materials Forum, 1994, Vol. 17, No. 3, pp. 301–307.
Malevskii Y.B. et al.: Effects of the annealing conditions on the phase changes taking place in thin composite aluminium-iron films, Avt. Svarka, 1971, Vol. No. 1, pp. 30–34.
Heumann T., Dittrich S.: Über die Kinetik der Reaktionen von festem und flüssigem Aluminium mit Eisen (Over the kinetics of the reactions of solid and liquid aluminium with iron), Zeitschrift für Metallkunde, 1959, Vol. 50, pp. 617–635.
Frerichs F.: Untersuchungen zum Kirkendall-Effekt im gesamten Konzentrationsbereich von binären Diffusionssystemen (Examinations about the Kirkendall-effect in the entire concentration-area of binary diffusion-systems), 2001.
Yilmaz M., Cöl M., Acet M.: Interface properties of aluminum/steel friction-welded components, Materials Characterization, 2002, Vol. 49, No. 5, pp. 421–429.
Marder A.R.: The metallurgy of zinc-coated steel, Progress in Materials Science, 2000, vol. 45, pp. 191–271.
Köster M., Schuhmacher B., Sommer D.: The influence of the zinc content on the lattice constants and structure of the intermetallic compound Fe2AI5, Steel Research, 2001, vol. 72, No. 9, pp. 371–375.
Scheider K., Kessler H.: Die Reaktion von festem Eisen mit Schmelzen zinkhaltiger Aluminiumlegierungen (The reaction of solid iron with meltdowns of zinccontaining aluminum-alloys), Metall, 1953, vol. 7, 15/16, pp. 608–618.
Achar D.R.G. et al.: Verbinden von Aluminium mit Stahl besonders durch Schweißen (III) (Connecting aluminum to steel particularly through welding (III)), Aluminium, 1980, vol. 56, 4, pp. 291–293.
Sun X., Stephens E.V., Khaleel M.A., Shao H., Kimchi M.: Resistance spot welding of aluminium alloy to steel with transition material — From process to performance — Part I: Experimental study, Welding Journal, June 2004, pp. 188-S-195-S.
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Figner, G., Vallant, R., Weinberger, T. et al. Friction Stir Spot Welds between Aluminium and Steel Automotive Sheets: Influence of Welding Parameters on Mechanical Properties and Microstructure. Weld World 53, R13–R23 (2009). https://doi.org/10.1007/BF03266697
Published:
Issue Date:
DOI: https://doi.org/10.1007/BF03266697