Abstract
A novel multi-functional tool with circumferential notches shape probe was proposed for friction stir lap welded dissimilar materials. The novel probe produced larger turbulent flow region (strain rate ≥10 s−1) by 185% and converged the plasticized materials below the probe top. The general hook and cold lap defects were eliminated, and the large metallurgical bonding area was acquired. The tensile shear load of the dissimilar 6082-T6/2A12-T4 joint reached 85% of the base 6082-T6 alloy. The sound Al/steel joint with the large bonding area and the limited diffusion bonding layer of 2 μm was achieved. The probe avoided the direct contact between the probe and steel sheet, and then eliminated the probe abrasion for soft/hard configuration. The circumferential notches shape probe has potential to achieve the reliable lap joint due to the eliminations of general defects and probe abrasion, large metallurgical bonding area as well as high joint performance.
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