A review on friction-based joining of dissimilar aluminum-steel joints

This article showcases details on enumerative information of dissimilar aluminum (Al) to steel welds manufactured using different friction-based welding processes with an emphasis on the description of the manufacturing process, influence of parameters, microstructural variations, formation of intermetallic compounds (IMCs), and variations in mechanical properties. Friction-based welding processes such as friction welding, friction stir welding, hybrid friction stir welding, friction stir spot welding, friction stir spot fusion welding, friction stir scribe welding, friction stir brazing, friction melt bonding, friction stir dovetailing, friction bit joining, friction stir extrusion, and friction stir assisted diffusion welding are analyzed for the formation of dissimilar Al-steel joints. It can be summarized that friction-based joining processes have great potential to obtain sound Al-steel joints. The amount of frictional heat applied decides the type and volume fraction of IMCs that subsequently affects mechanical joint properties. Process variations and novel process parameters can enhance joint properties.