Abstract
In this work, Friction Stir Welding (FSW) was applied to join a stainless steel 316L and an aluminum alloy 5083. Ranges of rotation and translation speeds of the tool were used to obtain welding samples with different heat input coefficients. Depending on the process parameters, the heat generated by FSW creates thin layers of Al-rich InterMetallic Compound (IMC) mainly composed of FeAl3, identified by energy dispersive spectrometry. Traces of Fe2Al5 were also depicted in some samples by X-ray diffraction analysis and transmission electron microscopy. Monotonous tensile tests performed on the weld joint show the existence of a maximum mechanical resistance for a judicious choice of rotation and translation speeds. It can be linked to an affected zone of average thickness of 15 µm which encompass the presence of IMC and the chaotic mixing caused by plastic deformation in this area. A thickness of less than 15 µm is not sufficient to ensure a good mechanical resistance of the joint. For a thickness higher than 15 µm, IMC layers become more brittle and less adhesive due to high residual stresses which induces numerous cracks after cooling. This leads to a progressive decrease of the ultimate shear stress supported by the bond.
Highlights
IntroductionNumerous fields of application can find advantages of the process such as automotive and railway industries [2]
Unlike traditional welding methods, Friction Stir Welding (FSW) is an assembly technique which occurs without additional metal and does not reach the melting point of the materials [1].Numerous fields of application can find advantages of the process such as automotive and railway industries [2]
Numerous studies concerning FSW were performed focusing on different aspects of the process: tool material [8], tool shoulder geometry [9], pin global geometry [10] and thread [11], material flow, and heat generated during the welding [12,13]
Summary
Numerous fields of application can find advantages of the process such as automotive and railway industries [2]. Critical technological fields such as air transport, the development of fuel tanks for aerospace applications and the nuclear industry use FSW to join alloys [3]. The FSW technology opens the possibility of joining materials difficult to weld by traditional fusion processes, such as. Industrial joining between such dissimilar materials still remains a technological challenge because of the numerous parameters which could affect the joint quality.
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