Effect of friction welding condition on joining phenomena and mechanical properties of friction welded joint between 6063 aluminium alloy and AISI 304 stainless steel

Abstract

Dissimilar metal joints have some advantages such as high functionality characteristics for the industrial usage. This paper describes the effect of friction welding condition on joining phenomena, tensile strength, and bend ductility of friction welded joints between Al-Mg-Si alloy (AA6063) and austenitic stainless steel (AISI 304). When joints were made at a friction pressure of 30MPa with a friction speed of 27.5s−1, the upsetting (deformation) occurred at the AA6063 side. The temperature on the weld interface increased with friction time, and it reached to 623K or over at a friction time of 1.5s or longer. When joints were made with a friction time of 1.5s and a forge pressure of 240MPa, all joints had the joint efficiency of approximately 100% and the fracture in the AA6063 base metal. Furthermore, those joints had the bend ductility of 90° in a single direction with no crack at the weld interface and did not have the intermetallic compound (IMC) interlayer on the weld interface. To obtain 100% joint efficiency with good joint, the joint should be made with the following conditions: a high forge pressure such as 240MPa, the opportune friction time that the temperature on the weld interface reached to about 623K or higher.