Microstructure, mechanical properties and formability of friction stir welded dissimilar materials of IF-steel and 6061 Al alloy

Semih Mahmut Aktarer; Dursun Murat Sekban; Tevfik Kucukomeroglu; Gencaga Purcek

doi:10.1007/s12613-019-1783-z

Volume 26 Issue 6

Jun. 2019

Turn off MathJax

Article Contents

Article Navigation > International Journal of Minerals, Metallurgy and Materials > 2019 > 26(6): 722-731

Semih Mahmut Aktarer, Dursun Murat Sekban, Tevfik Kucukomeroglu, and Gencaga Purcek, Microstructure, mechanical properties and formability of friction stir welded dissimilar materials of IF-steel and 6061 Al alloy, Int. J. Miner. Metall. Mater., 26(2019), No. 6, pp. 722-731. https://doi.org/10.1007/s12613-019-1783-z

Cite this article as:

Semih Mahmut Aktarer, Dursun Murat Sekban, Tevfik Kucukomeroglu, and Gencaga Purcek, Microstructure, mechanical properties and formability of friction stir welded dissimilar materials of IF-steel and 6061 Al alloy, Int. J. Miner. Metall. Mater., 26(2019), No. 6, pp. 722-731. https://doi.org/10.1007/s12613-019-1783-z

Citation:

PDF( 8508 KB)

Research Article

Microstructure, mechanical properties and formability of friction stir welded dissimilar materials of IF-steel and 6061 Al alloy

+ Author Affiliations

Corresponding author:
Gencaga Purcek E-mail: purcek@ktu.edu.tr
Received: 1 June 2018; Revised: 27 February 2019; Accepted: 28 February 2019

Abstract

Abstract

AA 6061 alloy and interstitial-free (IF) steel plates were joined by the friction stir welding (FSW) method, and the microstructure, mechanical properties, and biaxial stretch formability of the friction stir welded (FSWed) parts were investigated. The results indicate that the FSWed parts showed optimum tensile strength during FSW with the 0.4-mm offset position of the tool. The Fe₄Al₁₃ intermetallic compound formed in the defect-free intersection of AA 6061 and IF-steel plates during FSW. The hardness of the IF-steel part of the FSWed region increased almost 90% relative to its initial hardness of HV_0.2 105. The tensile and yield strengths of FSWed regions were approximately 170 MPa and 145 MPa, respectively. According to the formability tests, the Erichsen Index (EI) of the IF-steel, AA 6061, and the FSWed samples were determined to be 2.9 mm, 1.9 mm, and 2.1 mm, respectively. The EI of the FSWed sample was almost the same as that of the AA 6061 alloy. However, it decreased compared with that of the IF-steel. The force at EI (F_EI) was approximately 1180 N for the FSWed condition. This value is approximately 70% higher than that of AA 6061 alloy.
- friction stir welding;
- IF-steel;
- aluminum alloy;
- microstructure;
- mechanical properties;
- formability

FullText(HTML)

Supplements(0)

References(48)

References

[1]	R.Z. Xu, D.R. Ni, Q. Yang, C.Z. Liu, and Z.Y. Ma, Pinless friction stir spot welding of Mg–3Al–1Zn alloy with Zn interlayer, J. Mater. Sci. Technol., 32(2016), No. 1, p. 76.
[2]	X. Liu, S.H. Lan, and J. Ni, Analysis of process parameters effects on friction stir welding of dissimilar aluminum alloy to advanced high strength steel, Mater. Des., 59(2014), p. 50.
[3]	D.M. Sekban, O. Saray, S.M. Aktarer, G. Purcek, and Z.Y. Ma, Microstructure, mechanical properties and formability of friction stir processed interstitial-free steel, Mater. Sci. Eng. A, 642(2015), p. 57.
[4]	M. Movahedi, A.H. Kokabi, S.M. Seyed Reihani, W.J. Cheng, and C.J. Wang, Effect of annealing treatment on joint strength of aluminum/steel friction stir lap weld, Mater. Des., 44(2013), p. 487.
[5]	M.D. Sameer and A.K. Birru, Investigations on microstructural evolutions and mechanical properties of dual-phase 600 steel and AA6082–T6 aluminum alloy dissimilar joints fabricated by friction stir welding, Trans. Indian Inst. Met., 72(2019), No. 2, p. 353.
[6]	L. Wan and Y.X. Huang, Friction stir welding of dissimilar aluminum alloys and steels: a review, Int. J. Adv. Manuf. Technol., 99(2018), No. 5-8, p. 1781.
[7]	B. Seo, K.H. Song, and K. Park, Corrosion properties of dissimilar friction stir welded 6061 aluminum and HT590 steel, Met. Mater. Int., 24(2018), No. 6, p. 1232.
[8]	M. Thomä, G. Wagner, B. Straß, B. Wolter, S. Benfer, and W. Fürbeth, Ultrasound enhanced friction stir welding of aluminum and steel : Process and properties of EN AW 6061/DC04-joints, J. Mater. Sci. Technol., 34(2017), No. 1, p. 163.
[9]	P.H.C.P.D. Cunha, G.V.B. Lemos, L. Bergmann, A. Reguly, J.F.D. Santos, R.R. Marinho, and M.T.P. Paes, Effect of welding speed on friction stir welds of GL E36 shipbuilding steel, J. Mater. Res. Technol., 2018. https://doi.org/10.1016/j.jmrt.2018.07.014
[10]	F.H. Nie, H.G. Dong, S. Chen, P. Li, L.Y. Wang, Z.X. Zhao, X.T. Li, and H. Zhang, Microstructure and mechanical properties of pulse MIG welded 6061/A356 aluminum alloy dissimilar butt joints, J. Mater. Sci. Technol., 34(2018), No. 3, p. 551.
[11]	B.B. Wang, F.F. Chen, F. Liu, W.G. Wang, P. Xue, and Z.Y. Ma, Enhanced mechanical properties of friction stir welded 5083Al–H19 joints with additional water cooling, J. Mater. Sci. Technol., 33(2017), No. 9, p. 1009.
[12]	K.M. Venkatesh, M. Arivarsu, M. Manikandan, and N. Arivazhagan, Review on friction stir welding of steels, Mater. Today Proc., 5(2018), No. 5, p. 13227.
[13]	R.S. Mishra and Z.Y. Ma, Friction stir welding and processing, Mater. Sci. Eng. R, 50(2005), No. 1-2, p. 1.
[14]	M. Jafarzadegan, A. Abdollah-zadeh, A.H. Feng, T. Saeid, J. Shen, and H. Assadi, Microstructure and mechanical properties of a dissimilar friction stir weld between austenitic stainless steel and low carbon steel, J. Mater. Sci. Technol., 29(2013), No. 4, p. 367.
[15]	M.I. Costa, C. Leitão, A.L. Ramalho, and D.M. Rodrigues, Local improvement of structural steels high-friction properties by friction stir texturing, J. Mater. Process. Technol., 217(2015), p. 272.
[16]	S. Bozzi, A.L. Helbert-Etter, T. Baudin, B. Criqui, and J.G. Kerbiguet, Intermetallic compounds in Al 6016/IF–steel friction stir spot welds, Mater. Sci. Eng. A, 527(2010), No. 16-17, p. 4505.
[17]	Y.F. Sun, H. Fujii, N. Takaki, and Y. Okitsu, Microstructure and mechanical properties of dissimilar Al alloy/steel joints prepared by a flat spot friction stir welding technique, Mater. Des., 47(2013), p. 350.
[18]	M. Movahedi, A. H. Kokabi, and S.M. Seyed Reihani, Investigation on friction stir lap welding of aluminium to aluminium clad steel sheets, Sci. Technol. Weld. Joining, 17(2012), No. 3, p. 231.
[19]	K. Kimapong and T. Watanabe, Lap joint of A5083 aluminum alloy and SS400 steel by friction stir welding, Mater. Trans., 46(2005), No. 4, p. 835.
[20]	T.H. Wang, M. Komarasamy, K.M. Liu, and R.S. Mishra, Friction stir butt welding of strain-hardened aluminum alloy with high strength steel, Mater. Sci. Eng. A, 737(2018), p. 85.
[21]	B. Sundman, I. Ohnuma, N. Dupin, U.R. Kattner, and S.G. Fries, An assessment of the entire Al–Fe system including D03 ordering, Acta Mater., 57(2009), No. 10, p. 2896.
[22]	S.G. Sajan, M. Meshram, P. Srinivas, and S.R. Dey, Friction stir welding of aluminum 6082 with mild steel and its joint analyses, Int. J. Adv. Mater. Manuf. Charact., 3(2013), No. 1, p. 189.
[23]	K.K. Ramachandran, N. Murugan, and S. Shashi Kumar, Performance analysis of dissimilar friction stir welded aluminium alloy AA5052 and HSLA steel butt joints using response surface method, Int. J. Adv. Manuf. Technol., 86(2016), No. 9-12, p. 2373.
[24]	M. Merklein and A. Giera, Laser assisted friction stir welding of drawable steel-aluminium tailored hybrids, Int. J. Mater. Form., 1(2008), No.1, p. 1299.
[25]	S. Kundu, D. Roy, R. Bhola, D. Bhattacharjee, B. Mishra, and S. Chatterjee, Microstructure and tensile strength of friction stir welded joints between interstitial free steel and commercially pure aluminium, Mater. Des., 50(2013), p. 370.
[26]	K.N. Krishnan, On the formation of onion rings in friction stir welds, Mater. Sci. Eng. A, 327(2002), No. 2, p. 246.
[27]	K. Kumar and S.V. Kailas, The role of friction stir welding tool on material flow and weld formation, Mater. Sci. Eng. A, 485(2008), No. 1-2, p. 367.
[28]	M.W. Mahoney, C.G. Rhodes, J.G. Flintoff, W.H. Bingel, and R.A. Spurling, Properties of friction-stir-welded 7075 T651 aluminum, Metall. Mater. Trans. A, 29(1998), No. 7, p. 1955.
[29]	M.A. Sutton, B. Yang, A.P. Reynolds, and R. Taylor, Microstructural studies of friction stir welds in 2024-T3 aluminum, Mater. Sci. Eng. A, 323(2002), No. 1-2, p. 160.
[30]	D.M. Sekban, S.M. Aktarer, H. Zhang, P. Xue, Z.Y. Ma, and G. Purcek, Microstructural and mechanical evolution of a low carbon steel by friction stir processing, Metall. Mater. Trans. A, 48(2017), No. 8, p. 3869.
[31]	M.A. Abdulstaar, K.J. Al-Fadhalah, and L. Wagner, Microstructural variation through weld thickness and mechanical properties of peened friction stir welded 6061 aluminum alloy joints, Mater. Charact., 126(2017), p. 64.
[32]	G. Çam and S. Mistikoglu, Recent developments in friction stir welding of Al-alloys, J. Mater. Eng. Perform., 23(2014), No. 6, p. 1936.
[33]	H.A. Derazkola and M. Elyasi, Feasibility study on aluminum alloys and A441 AISI steel joints by friction stir welding, Int. J. Adv. Des. Manuf. Technol, 7(2014), No. 4, p. 99.
[34]	H. Bang, H. Bang, G. Jeon, I. Oh, and C. Ro, Gas tungsten arc welding assisted hybrid friction stir welding of dissimilar materials Al6061–T6 aluminum alloy and STS304 stainless steel, Mater. Des., 37(2012), p. 48.
[35]	R.S. Coelho, A. Kostka, J.F. dos Santos, and A. Kaysser-Pyzalla, Friction-stir dissimilar welding of aluminium alloy to high strength steels: Mechanical properties and their relation to microstructure, Mater. Sci. Eng. A, 556(2012), p. 175.
[36]	X. Liu, S.H. Lan, and J. Ni, Electrically assisted friction stir welding for joining Al 6061 to TRIP 780 steel, J. Mater. Process. Technol., 219(2015), p. 112.
[37]	T. Tanaka, T. Morishige, and T. Hirata, Comprehensive analysis of joint strength for dissimilar friction stir welds of mild steel to aluminum alloys, Scripta Mater., 61(2009), No. 7, p. 756.
[38]	T. Watanabe, H. Takayama, and A. Yanagisawa, Joining of aluminum alloy to steel by friction stir welding, J. Mater. Process. Technol., 178(2006), No. 1-3, p. 342.
[39]	C.M. Chen and R. Kovacevic, Joining of Al 6061 alloy to AISI 1018 steel by combined effects of fusion and solid state welding, Int. J. Mach. Tools Manuf., 44(2004), No. 11, p. 1205.
[40]	Y. Kusuda, Honda develops robotized FSW technology to weld steel and aluminum and applied it to a mass-production vehicle, Ind. Robot–I.J. Rob. Res. Appl., 40(2013), No. 3, p. 208.
[41]	O. Saray, Biaxial deformation behavior and formability of precipitation hardened ultra-fine grained (UFG) Cu–Cr–Zr alloy, Mater. Sci. Eng. A, 656(2016), p. 120.
[42]	B. Sadeghian, A. Taherizadeh, and M. Atapour, Simulation of weld morphology during friction stir welding of aluminum–stainless steel joint, J. Mater. Process. Technol., 259(2018), p. 96.
[43]	O. Saray, G. Purcek, I. Karaman, and H.J. Maier, Formability of ultrafine-grained interstitial-free steels, Metall. Mater. Trans. A, 44(2013), No. 9, p. 4194.
[44]	O. Saray, G. Purcek, I. Karaman, and H.J. Maier, Improvement of formability of ultrafine-grained materials by post-SPD annealing, Mater. Sci. Eng. A, 619(2014), p. 119.
[45]	M.P. Manahan, A.E. Browning, A.S. Argon, and O.K. Harling, Miniaturized disk bend test technique development and application, ASTM Spec. Tech. Publ., (1986), p. 17.
[46]	Y.M. Yue, Z.W. Li, S.D. Ji, Y.X. Huang, and Z.L. Zhou, Effect of reverse-threaded pin on mechanical properties of friction stir lap welded alclad 2024 aluminum alloy, J. Mater. Sci. Technol., 32(2016), No. 7, p. 671.
[47]	S. Mironov, Y.S. Sato, and H. Kokawa, Microstructural evolution during friction stir-processing of pure iron, Acta Mater., 56(2008), No. 11, p. 2602.
[48]	M.E. Cetin, M. Demirtas, H. Sofuoglu, Ö.N. Cora, and G. Purcek, Effects of grain size on room temperature deformation behavior of Zn–22Al alloy under uniaxial and biaxial loading conditions, Mater. Sci. Eng. A, 672(2016), p. 78.