Dissimilar Metal T-Joint of Aluminum and Steel Formed by Friction Stir Extrusion

Abstract

This paper extends the capabilities of the Friction Stir Extrusion process by demonstrating the ability to join aluminum and steel in a T-joint configuration. Friction Stir Welding techniques are used to extrude aluminum into a concave groove cut into the top edge of a steel plate. The Friction Stir Extrusion process forms a mechanical joint avoiding many of the detrimental effects from the formation of intermetallic compounds. Also, eliminating many of the issues of rapid tool wear associated with the Friction Stir Welding of steel. The T-joint configuration would allow joining of dissimilar materials in a variety of applications, such as joining an aluminum skin to a steel/titanium frame. Such construction would allow for a strong, lightweight, and corrosion resistant structures. Strength of the joint was tested in tension to determine the quality of the weld. The average failure strength of the joint was 47.66 Kgf/mm.