Abstract
The formation of thick intermetallic compounds (IMC) at the joint interface between aluminum alloy and steel has been the major barrier for adopting Al-Fe bimetallic structures in safety-critical structures. Although friction stir welding (FSW) has recently shown some promise, the progress has been slow towards effectively controlling detrimental IMCs due to a lack of a better understanding of the effects of friction stir conditions on the Al-Fe interfacial transition layer development. This study presents a carefully designed FSW experiment to show how a thick intermetallic layer can be reduced to a nanoscale amorphous phase through control of friction stir conditions. Its implications on practical conditions for joining aluminum alloy and steel without detrimental IMCs are also discussed in light of both the experimental results and underlying mechanical and physical phenomena.
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