Dissimilar welding of aluminum to AlSi-coated steel sheets using refill friction stir spot welding: A feasibility study

Tong SHEN; Banglong FU; Ting CHEN; U.F.H. SUHUDDIN; B. KLUSEMANN

doi:10.21741/9781644903131-189

–

Dissimilar welding of aluminum to AlSi-coated steel sheets using refill friction stir spot welding: A feasibility study

SHEN Tong, FU Banglong, CHEN Ting, SUHUDDIN Uceu, KLUSEMANN Benjamin

Abstract. The main objective of this study was to assess and enhance the weldability of AA6016-T4 to AlSi-coated press-hardened steel (PHS), with a focus on investigating the impact of the AlSi coating on the mechanical properties of welded joints. Variations in tool rotation speed, dwell time, and plunge speed were performed to observe their effects on the joint behavior. It was observed that the protective AlSi-coating significantly influences the mechanical strength of the welded joint. Notably, the removal of the AlSi coating resulted in a substantial increase in joint mechanical strength. To systematically assess joint lap-shear strength under static loading conditions, Design of Experiment technique was employed. The influence of the process parameters on joint strength was thoroughly evaluated.

Keywords
Refill Friction Stir Spot Welding, Aluminum, Steel, Dissimilar Materials Joining Lap-Shear Properties

Published online 4/24/2024, 9 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: SHEN Tong, FU Banglong, CHEN Ting, SUHUDDIN Uceu, KLUSEMANN Benjamin, Dissimilar welding of aluminum to AlSi-coated steel sheets using refill friction stir spot welding: A feasibility study, Materials Research Proceedings, Vol. 41, pp 1705-1713, 2024

DOI: https://doi.org/10.21741/9781644903131-189

The article was published as article 189 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] COMMUNICATION FROM THE COMMISSION TO THE EUROPEAN PARLIAMENT. A Clean Planet for all A European strategic long-term vision for a prosperous, modern, competitive and climate neutral economy, 2018. https://eur-lex.europa.eu/legal-content/EN/TXT/?uri=CELEX:52018DC0773. Lesch, N. Kwiaton, F.B. Klose, Advanced High Strength Steels (AHSS) for Automotive Applications − Tailored Properties by Smart Microstructural Adjustments, Steel Res. Int. 88 (2017) 1700210. https://doi.org/10.1002/srin.201700210
[2] C. Lesch, N. Kwiaton, F.B. Klose, Advanced High Strength Steels (AHSS) for Automotive Applications − Tailored Properties by Smart Microstructural Adjustments, Steel Res. Int. 88 (2017) 1700210. https://doi.org/10.1002/srin.201700210
[3] A.S.M. International, ed., ASM Handbook Volume 1: Properties and Selection: Irons, Steels, and High-Performance Alloys, 10th edition, ASM International, Materials Park, Ohio, 1990.
[4] A.I.H. Committee, ASM Handbook Volume 2: Properties and Selection: Nonferrous Alloys and Special-purpose Materials, ASM International, 1990. https://books.google.de/books?id=wxA7AQAAIAAJ
[5] M.E. Schlesinger, E.M. Mueller, ASM Handbook, Volume 3: Alloy Phase Diagrams, ASM International, Materials Park, Ohio, 1983.
[6] L. Tricarico, R. Spina, D. Sorgente, et al., Effects of heat treatments on mechanical properties of Fe/Al explosion-welded structural transition joints, Mater. Des. 30 (2009) 2693–2700. https://doi.org/10.1016/j.matdes.2008.10.010
[7] R.W. Richards, R.D. Jones, P.D. Clements, et al., Metallurgy of continuous hot dip aluminizing, Int. Mater. Rev. 39 (1994) 191–212. https://doi.org/10.1179/imr.1994.39.5.191.
[8] J. Yang, J.P. Oliveira, Y. Li, et al., Laser techniques for dissimilar joining of aluminum alloys to steels: A critical review, J. Mater. Process. Technol. 301 (2022). https://doi.org/10.1016/j.jmatprotec.2021.117443
[9] J. Chen, B. Shalchi Amirkhiz, R. Zhang, et al., On the Joint Formation and Interfacial Microstructure of Cold Metal Transfer Cycle Step Braze Welding of Aluminum to Steel Butt Joint, Metall. Mater. Trans. A. 51 (2020) 5198–5212. https://doi.org/10.1007/s11661-020-05917-8
[10] G. Chen, J. Liu, X. Shu, et al., Beam scanning effect on properties optimization of thick-plate 2A12 aluminum alloy electron-beam welding joints, Mater. Sci. Eng. A. 744 (2019) 583–592. https://doi.org/10.1016/j.msea.2018.12.034
[11] M.J. Torkamany, S. Tahamtan, J. Sabbaghzadeh, Dissimilar welding of carbon steel to 5754 aluminum alloy by Nd:YAG pulsed laser, Mater. Des. 31 (2010) 458–465. https://doi.org/10.1016/j.matdes.2009.05.046
[12] G. Qin, Z. Lei, Y. Su, et al., Large spot laser assisted GMA brazing–fusion welding of aluminum alloy to galvanized steel, J. Mater. Process. Technol. 214 (2014) 2684–2692. https://doi.org/10.1016/j.jmatprotec.2014.06.011
[13] J. Yang, Z. Yu, Y. Li, et al., Influence of alloy elements on microstructure and mechanical properties of Al/steel dissimilar joint by laser welding/brazing, Weld. World. 62 (2018) 427–433. https://doi.org/10.1007/s40194-017-0540-z
[14] U. Dressler, G. Biallas, und U. Alfaro Mercado, „Friction stir welding of titanium alloy TiAl6V4 to aluminium alloy AA2024-T3“, Mater. Sci. Eng. A, Bd. 526, Nr. 1–2, S. 113–117, Nov. 2009. https://doi.org/10.1016/j.msea.2009.07.006
[15] Y. Kusuda, Honda develops robotized FSW technology to weld steel and aluminum and applied it to a mass‐production vehicle, Ind. Robot Int. J. 40 (2013) 208–212. https://doi.org/10.1108/01439911311309889
[16] L. SELOVA, H. AYDIN, O. TUNCEL, et al., Mechanical Properties of Resistance Spot Welded Three-Sheet Stack Joints of Dissimilar Steels in Different Welding Time, (2019).
[17] T. Matsuda, K. Owada, A. Numata, et al., Influence of interfacial structure on the fracture behavior of friction stir spot welded dissimilar joints, Mater. Sci. Eng. A. 772 (2020) 138743. https://doi.org/10.1016/j.msea.2019.138743
[18] C. Schilling, J. dos Santos, Method and device for joining at least two adjoining work pieces by friction welding, (2004).
[19] Y. Ding, Z. Shen, A.P. Gerlich, Refill friction stir spot welding of dissimilar aluminum alloy and AlSi coated steel, J. Manuf. Process. 30 (2017) 353–360. https://doi.org/10.1016/j.jmapro.2017.10.006
[20] DIN EN ISO 14273, Specimen dimensions and procedure for tensile shear testing resistance spot, seam and embossed projection welds. In: DIN, the German Institute for Standardization, 2014.