Abstract
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.
Highlights
The microstructural changes of friction stir spot welding (FSSW) are similar to the friction stir welding (FSW) process such as stir zone, thermomechanically affected zone (TMAZ), and heat-affected zone (HAZ), as frictional heat softens the base material and subsequent recrystallization leads to joint formation.[125–141]
Formation of the intermetallic compounds (IMCs) layer with phases of Fe2Al5 and Fe4Al13 is noted when low carbon steel is welded to the Al alloy of 6061-T6.148 Microstructural variations of friction stir spot fusion welding (FSSFW) of Al–steel joint suggest that the layer of IMCs is thicker in the case of fusion zone relative to the deformation zone due to the strong interdiffusion phenomenon at the fusion zone
A review on process description, influence of parameters, microstructural variations, formation of IMCs, and variations in mechanical properties is presented for various friction-based welding processes
Summary
The electrochemical difference between Al and steel is 1.22 volts.[1,6] These dissimilarities in thermophysical, chemical, and mechanical properties of Al–steel materials lead to disadvantages such as formation of intermetallic compounds (IMCs), heat-affected zone (HAZ), metallurgical precipitation, defects, distortion, and deterioration of mechanical joint properties.[1,3,6,9,10]. Considering these factors, joining processes such as brazing,[11–13] gas tungsten arc welding (GTAW),[14,15] gas metal arc welding,[16,17] metal inert gas welding,[18] laser welding,[14,19–22] hybrid welding,[23–26] resistance spot welding,[27–29] explosive welding,[30] magnetic pulse welding,[31,32] cold metal transfer,[33,34] ultrasonic welding,[35] and friction-based welding processes[1,3,6] are investigated in different literature studies. Comprehensive understanding is developed through this article, which showcases details on dissimilar Al–steel joint manufactured by the above-mentioned friction-based welding for its process description, influence of parameters, microstructural variations, formation of IMCs, and variations in mechanical properties
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