Abstract
With continuous growth and stringent demand for weight reduction in automotive structures, the automotive industry has shown an increasing interest in dissimilar aluminium–steel welding. Dissimilar lap joint between AA6351 alloys of 2 mm thickness and DP800 advanced high-strength dual-phase steel of 1 mm thickness has been attempted and joined successfully by friction stir welding with different combinations of parameters. The experimental results of this research work clearly indicate that joining of advanced high-strength steel and aluminium in lap-joint configuration is quite feasible with friction stir welding. Microstructural characterization has been performed by X-ray diffraction (XRD) technique and scanning electron microscopy (SEM). An intermetallic compounds layer was found in the interface of steel and aluminium with thickness of less than \(7 \,\upmu \hbox {m}\) and it was identified as \(\hbox {Al}_{2}\mathrm{Fe}\) and \(\hbox {Al}_{3}\mathrm{Fe}\) by XRD method. Thermal cycle has been measured and correlated with the microstructure. Shear tensile test has been performed for determining the maximum failure load for different combinations of parameters. Finally, mechanical properties and microstructural observation are correlated with each other.
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