Abstract
The stirring tools made of steels are easily worn in traditional friction stir welding (FSW) of Al alloy to steels, which limits their wide application in industry. Here, we reported a new FSW method with no contacting between the tool and the steel plate, and an ordinary H13 steel tool can be used in this case. In this study, thickened Al alloy plate was applied during FSW of 1060Al to SUS304 stainless steel. The results showed that a high-quality joint was successfully acquired at an appropriate thickness difference of 0.7 mm between Al and steel plates, where an excellent metallurgical bonding achieved in the Al-steel interface. Microstructure characterization revealed a thin interface layer (< 1 μm) consisted of Al5Fe2 intermetallic compound (IMC) and Al13Fe4 IMC as well as Al-based solid solution with enrichment of Ni. The joint failed at the heat affected zone of Al side with a high strength of 104 MPa (95% of 1060Al). This study brings a low-cost and effective method in FSW of Al alloy and high fusion-point metals, and can realize long-distance and high-quality welding in industry.
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