4.6 Article

Interface stability and fracture mechanism of Al/Steel friction stir lap joints by novel designed tool

Journal

Publisher

ELSEVIER SCIENCE SA
DOI: 10.1016/j.jmatprotec.2021.117425

Keywords

Al/steel; Friction stir lap welding; Novel tool design; Interface formation; Mechanical properties; Fracture mechanism

Funding

  1. Youth Program of National Natural Science Foundation of China [52001099]
  2. Natural Science Foundation of Heilongjiang Province [JJ2020JQ085]
  3. National Natural Science Foundation of China [52175301]
  4. Heilongjiang Postdoctoral Foundation [LBH-Z20055]

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In this study, a novel welding tool with an enlarged pin design was developed to solve the hook feature and insufficient interface deformation in Al/steel friction stir lap welded joints. The results showed that the welding tool enhanced the interface deformation effect and eliminated the hook feature. Additionally, four different interface failure modes were observed during the shearing process, with a clear interval characteristic in the occurrence, development, and transfer of interface failure.
A novel welding tool, characterized by the enlarged pin design was developed to solve the hook feature or insufficient interface deformation for Al/steel friction stir lap welded joints. The welding tool enhanced the interface deformation effect and eliminated hook feature. The thickness of the intermetallic compound (IMC) layer at the interface decreased from 3.3 mu m to 0.46 mu m, when the welding speed increased from 30 mm/min to 300 mm/min. The laminated structure composed of IMCs and fine steel grains gradually disappeared, with the interface gradually changing from serrated to straight as welding speed increased. The nanohardness value of the microstructure reached 9.4 +/- 0.3 GPa at a distance of 10 mu m from the interface layer. Due to the larger metallurgical bonding area, the best line load 499.4 N/mm reached 52 % of the 3 mm 6082-T6 alloy, which was obtained at the rotational speed of 1200 r/min and the welding speed of 50 mm/min. Four different interface failure modes were found and established during the shearing process. The strain concentration phenomenon of the successive occurrence, development and transfer of interface failure presented obvious interval character-istics in time and space.

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