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RESEARCH PRODUCT

Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

Davide CampanellaAttilio MasnataGianluca BuffaLivan FratiniM. Wasif SafeenP. Russo Spena

subject

0209 industrial biotechnologyMaterials sciencePolymers and PlasticsCarbon steelAlloyContext (language use)02 engineering and technologyWeldingengineering.materialIndustrial and Manufacturing Engineeringlaw.invention020901 industrial engineering & automationAA6016 aluminum alloy0203 mechanical engineeringlawFriction stir weldingComposite materialJoint (geology)Tensile testingFriction stir welding (FSW)Mechanical EngineeringDissimilar materialWelding parametersDissimilar materialsAA6016 aluminum alloy; DC05 low carbon steel; Dissimilar materials; Friction stir welding (FSW); Welding parameters020303 mechanical engineering & transportsLap jointMechanics of MaterialsDC05 low carbon steelengineering

description

Widespread use of aluminum alloys for the fabrication of car body parts is conditional to the use of appropriate welding methods, especially if dissimilar welding must be performed with automotive steel grades. Friction stir welding (FSW) is considered to be a reasonable solution to obtain sound aluminum-steel joints. In this context, this work studies the effects of tool position and force control in dissimilar friction stir welding of AA6061 aluminum alloy on DC05 low carbon steel in lap joint configuration, also assessing proper welding parameter settings. Naked eye and scanning electron microscopy (SEM) have been used to detect macroscopic and microscopic defects in joints, as well as to determine the type of intermixture between aluminum and steel. The joint strength of sound joints has been assessed by shear tension test. Results point out that tool force control allows for obtaining joints with better quality and strength in a wider range of process parameters. A process window has been determined for tool force conditions to have joints with adequate strength for automotive purposes.

yearjournalcountryeditionlanguage
2020-02-24
10.1007/s40436-019-00290-1http://hdl.handle.net/10447/410429