Effects of tool positioning on joint interface microstructure and fracture strength of friction stir lap Al-to-steel welds

Chen, Z.W., Yazdanian, S. and Littlefair, G. 2013, Effects of tool positioning on joint interface microstructure and fracture strength of friction stir lap Al-to-steel welds, Journal of materials science, vol. 48, no. 6, pp. 2624-2634.

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Title Effects of tool positioning on joint interface microstructure and fracture strength of friction stir lap Al-to-steel welds
Author(s) Chen, Z.W.
Yazdanian, S.
Littlefair, G.
Journal name Journal of materials science
Volume number 48
Issue number 6
Start page 2624
End page 2634
Total pages 11
Publisher Springer
Place of publication Berlin, Germany
Publication date 2013-03
ISSN 0022-2461
1573-4803
Summary Friction stir lap welding (FSLW) experiments have been conducted to study the effects of tool positioning on microstructures formed in the Al-to-steel interface region and on joint strength, defined as maximum applied force over the width (F m/w s) of the test sample, of the welds. Various pin positioning and speed conditions were used in the FSLW experiments followed by microstructure examination on the interface regions and tensile-shear testing on the welds, including an examination on crack propagation in mixed stir zone. It was found that when the pin was close to the bottom steel piece, Al-to-steel reaction occurred resulting in intermetallic outbursts formed along the interface. This represents the case of incomplete metallurgical joint. When the pin was lowered to just reach the steel, a thin and continued interface intermetallic layer formed. Evidences and consideration on growth kinetics have suggested that the layer could only remain thin (≤2.5 μm) during FSLW. This layer could bear a high load during tensile-shear testing and the adjacent aluminium deformed and fractured instead. The resulting F m/w s was high. When the pin penetrated to steel, F m/w s reduced due to brittle fracture being dominant inside mixed stir zone. Evidences have shown that the amount of penetration and speed condition during FSLW do not have large effects on F m/w s.
Language eng
Field of Research 091006 Manufacturing Processes and Technologies (excl Textiles)
Socio Economic Objective 970109 Expanding Knowledge in Engineering
HERDC Research category C1 Refereed article in a scholarly journal
Persistent URL http://hdl.handle.net/10536/DRO/DU:30051073

Document type: Journal Article
Collection: School of Engineering
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