Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

doi:10.1007/s40436-019-00290-1

Advances in Manufacturing ›› 2020, Vol. 8 ›› Issue (1): 59-71.doi: 10.1007/s40436-019-00290-1

Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

M. Wasif Safeen¹, P. Russo Spena², G. Buffa³, D. Campanella³, A. Masnata³, L. Fratini³

1 Faculty of Science and Technology, Free University of Bozen-Bolzano, 39100 Bolzano, Italy;
2 Department of Management and Production Engineering, Polytechnic University of Turin, 10129 Torino, Italy;
3 Department of Engineering, University of Palermo, 90128 Palermo, Italy

收稿日期:2019-07-12 修回日期:2019-12-05 出版日期:2020-03-25 发布日期:2020-03-07
通讯作者: M. Wasif Safeen E-mail:mianwasif.safeen@natec.unibz.it

Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

M. Wasif Safeen¹, P. Russo Spena², G. Buffa³, D. Campanella³, A. Masnata³, L. Fratini³

1 Faculty of Science and Technology, Free University of Bozen-Bolzano, 39100 Bolzano, Italy;
2 Department of Management and Production Engineering, Polytechnic University of Turin, 10129 Torino, Italy;
3 Department of Engineering, University of Palermo, 90128 Palermo, Italy

Received:2019-07-12 Revised:2019-12-05 Online:2020-03-25 Published:2020-03-07
Contact: M. Wasif Safeen E-mail:mianwasif.safeen@natec.unibz.it

摘要/Abstract

摘要： Widespread use of aluminum alloys for the fabrication of car body parts is conditional to the use of appropriate welding methods, especially if dissimilar welding must be performed with automotive steel grades. Friction stir welding (FSW) is considered to be a reasonable solution to obtain sound aluminum-steel joints. In this context, this work studies the effects of tool position and force control in dissimilar friction stir welding of AA6061 aluminum alloy on DC05 low carbon steel in lap joint configuration, also assessing proper welding parameter settings. Naked eye and scanning electron microscopy (SEM) have been used to detect macroscopic and microscopic defects in joints, as well as to determine the type of intermixture between aluminum and steel. The joint strength of sound joints has been assessed by shear tension test. Results point out that tool force control allows for obtaining joints with better quality and strength in a wider range of process parameters. A process window has been determined for tool force conditions to have joints with adequate strength for automotive purposes.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00290-1.pdf

关键词: AA6016 aluminum alloy, Dissimilar materials, DC05 low carbon steel, Friction stir welding (FSW), Welding parameters

Abstract: Widespread use of aluminum alloys for the fabrication of car body parts is conditional to the use of appropriate welding methods, especially if dissimilar welding must be performed with automotive steel grades. Friction stir welding (FSW) is considered to be a reasonable solution to obtain sound aluminum-steel joints. In this context, this work studies the effects of tool position and force control in dissimilar friction stir welding of AA6061 aluminum alloy on DC05 low carbon steel in lap joint configuration, also assessing proper welding parameter settings. Naked eye and scanning electron microscopy (SEM) have been used to detect macroscopic and microscopic defects in joints, as well as to determine the type of intermixture between aluminum and steel. The joint strength of sound joints has been assessed by shear tension test. Results point out that tool force control allows for obtaining joints with better quality and strength in a wider range of process parameters. A process window has been determined for tool force conditions to have joints with adequate strength for automotive purposes.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00290-1.pdf

Key words: AA6016 aluminum alloy, Dissimilar materials, DC05 low carbon steel, Friction stir welding (FSW), Welding parameters

M. Wasif Safeen, P. Russo Spena, G. Buffa, D. Campanella, A. Masnata, L. Fratini. Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications[J]. Advances in Manufacturing, 2020, 8(1): 59-71.

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Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

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