Abstract
Aluminum alloy and stainless steel were joined by a continuous-drive axial friction welding machine in this study. The effects of welding parameters on the morphology, microstructure, microhardness, tensile strength, and fracture surface of dissimilar joints were analyzed. The distribution, thickness, and composition of intermetallic compound (IMC) were also discussed. Results showed that the formation of flash only was on the aluminum side because 6061 Al underwent extensive deformation during welding. Al and Fe elements diffused at the bonding interface and formed the IMC layer. The IMC thickness near the 1/2 radius was the smallest, and the thinnest at the center region. With the increase of friction pressure, the tensile strength of joint first increased and then decreased. When forge pressure was below 220 MPa, joint strength was approximately linearly related to the forge pressure. Edge regions of joints had achieved metallurgical bonding. The central region was the weak joining, and the fracture surface contained some cracks, IMCs, and a small amount of dimples.
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