Abstract
The widely investigated Al/steel laminated structures are challenged with subsequent plastic deformation due to the prone generation of interfacial brittle intermetallic compound layer. To overcome this drawback, a recently proposed thermomechanical forming technology as friction stir–assisted double-sided incremental plastic forming with synchronous solid-state interfacial bonding is utilized to fabricate Al/steel laminated structures. Typical interfacial bonding-forming performances produced by a series of experiments classified as sound bonding, de-bonding, over-thinning, penetration and crack are individually assessed. Local working peak temperature and maximum forming force in loading area are recorded and evaluated during stable bonding-forming stage. Considering the heat-force coupling effect, a pressure-strain-temperature–based prediction model is modified to assess interfacial quality, which is conformed to experimental results. This work can help obtain proper process window to successfully fabricate Al/steel laminated parts and shall also inspire to build guidance of related thermomechanical joining-with-forming processes to achieve high interfacial performance.
Highlights
The demands of lightweight laminated structures are emerging in shipping, maritime, and kitchenware industries because of their comprehensive performance in high relative strength, vibration absorption and corrosion resistance
Chung et al [8] investigated the interfacial performance of the joint of dissimilar steels F82H/SUS304, which indicated that the sheets are just mixed without diffusion
Friction stir dovetailing (FSD) is another newly developed process to join dissimilar materials [10], which can simultaneously produce interfacial metallurgical bonding mixed with mechanical occlusion
Summary
The demands of lightweight laminated structures are emerging in shipping, maritime, and kitchenware industries because of their comprehensive performance in high relative strength, vibration absorption and corrosion resistance. Li et al [18] developed a process window for a novel friction stir assisted thermomechanical forming process to fabricate Al/steel solid-state bonded parts with synchronous incremental plastic deformation. The high-speed rotational rod-shaped rigid MT generates adequate friction stir induced heat on the contact area conducted to sheets and tools to complete the dissimilar thermomechanical bonding. Ruled by the coupling effects of friction induced heat and loading force, interfacial solid-state bonding is achieved at localized loading area with incremental plastic deformation. In this step, the process parameters can be adjusted according to specific materials and forming conditions to control frictional heat input. The total equivalent plastic strain for a localized loading area can be calculated via the strain component εt ,
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