Interface microstructure study of friction stir lap joint of AC4C cast aluminum alloy and zinc-coated steel

Abstract AC4C cast Al alloy and zinc-coated steel are successfully lap jointed using friction stir welding. The interface microstructure is investigated using optical microscopy, scanning electron microscopy and X-ray diffraction. The mechanical properties of the joints are evaluated using tensile test. Experimental results show that the lap joint consisted of four part structures, i.e. stir zone structure of Al alloy, new intermetallic compounds layer, old intermetallic compounds layer of original zinc coat and base material of steel. The thickness of intermetallic compounds layer increases with decreasing welding speeds and has a significant effect on the strengths of the joints. Heavy thickness of intermetallic compounds layer seriously deteriorates the mechanical properties of the joints. The intermetallic compounds layer mainly contains Fe2Al5 and Fe4Al13.

[1]  L. Murr,et al.  Intercalation vortices and related microstructural features in the friction-stir welding of dissimilar metals , 1998 .

[2]  R. Pretorius.  Phase sequence of silicide formation at metal-silicon interfaces , 1990 .

[3]  J. Tsujino,et al.  Ultrasonic butt welding of aluminum, aluminum alloy and stainless steel plate specimens. , 2002, Ultrasonics.

[4]  B. Raj,et al.  Corrosion and microstructural aspects of dissimilar joints of titanium and type 304L stainless steel , 2003 .

[5]  Yutaka S. Sato,et al.  Constitutional liquation during dissimilar friction stir welding of Al and Mg alloys , 2004 .

[6]  I. Ansara,et al.  Al-Mg COST 507 Thermochemical database for light metal alloys , 1998 .

[7]  R. D. Reus,et al.  Use of the effective heat of formation rule for predicting phase formation sequence in AlNi systems , 1990 .

[8]  Jiuchun Yan,et al.  Microstructure characteristics and performance of dissimilar welds between magnesium alloy and aluminum formed by friction stirring , 2005 .

[9]  L. Murr,et al.  Friction-stir welding: microstructural characterization , 1998 .

[10]  Ying Li,et al.  Fundamental Issues and Industrial Applications of Friction-Stir Welding , 2000 .

[11]  L. Murr,et al.  Microstructures in friction-stir welded dissimilar magnesium alloys and magnesium alloys to 6061-T6 aluminum alloy , 2004 .

[12]  S. Jung,et al.  Void Free Friction Stir Weld Zone Of The Dissimilar 6061 Aluminum And Copper Joint By Shifting The Tool Insertion Location , 2004 .

[13]  F. W. Saris,et al.  Prediction of phase formation sequence and phase stability in binary metal-aluminum thin-film systems using the effective heat of formation rule , 1991 .

[14]  K. Ikeuchi,et al.  Friction-Stir-Welded Lap Joint of Aluminum to Zinc-Coated Steel , 2005 .

[15]  Y. Wang,et al.  Application of electric discharge process in joining aluminum and stainless steel sheets , 2003 .

[16]  Seung-Boo Jung,et al.  Effect of friction welding parameters on mechanical and metallurgical properties of aluminium alloy 5052–A36 steel joint , 2003 .

[17]  Seung-Boo Jung,et al.  The joint properties of dissimilar formed Al alloys by friction stir welding according to the fixed location of materials , 2003 .

[18]  Masao Ushio,et al.  Dissimilar Metal Joining of Aluminum to Steel by MIG Arc Brazing Using Flux Cored Wire , 2003 .