Review on Dissimilar Friction Stir Welding of ...

National Conference on Advances in Research and Innovations in Mechanical Engineering, Material Science, Industrial Engineering and Management

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Review on Dissimilar Friction Stir Welding of Aluminium to Steel Sameer MD and Anil Kumar Birru Abstract--- Aluminium and steel are widely in used in various engineering applications, aluminum due to its satisfactory strength and low density, and steels because of its high toughness and good corrosion resistance. There is a worthy demand in automobile industry for the joining of dissimilar aluminum alloys and steels due to weight reduction and properties obtained from the combination of the both the materials. In recent years a lot of investigations have been carried out on dissimilar friction stir welding because of its solid state process. The present review provides a broad awareness of dissimilar joining of Aluminium alloys to steels by friction stir welding process. Friction stir parameters like tool rotational speed, translational speed, tool tilt angle, position of the work piece and tool offset for the dissimilar Aluminium alloys and steels are discussed in the present review. Furthermore, joint strength, microstructure and intermetallic compound generation for Aluminium –steel FSW system have been discussed in this article. Also, the new developments and future scope of dissimilar Aluminium –steel FSW system have been addressed. Keywords--- Dissimilar, Aluminium, steel

I.

friction

stir

concept is now a trend in automotive industry. The conventional joining techniques commonly used for joining the similar and dissimilar materials are shown in figure 1.2. The fusion welding process is not recommended to join al-steel because of formation Intermetallic layer compound (IMC), layer due high associated heat input during fusion process that resulted in weak joint [2]

Figure 1.1 Material distribution of total vehicle curb weight in kilogram (Mayyas et al., 2012).

welding,

INTRODUCTION

J

oining of dissimilar materials via any welding process is always difficult because of the vast dissimilarities in mechanical and metallurgical properties. Advanced hybrid lightweight materials are very much needed for the automotive industry [1] (Figure 1.1). Steels have attractive properties such as recyclability, low cast and historically the materials are preferred for structural application in automobile industry however single metal cannot fit all applications therefore multi- materials Sameer MD,Research Scholar,Department of Mechanical Engineering, NIT Manipur, Imphal, India. Email:[email protected] AK Birru, Assistant Professor, Department of Mechanical Engineering, NIT Manipur, Imphal, India. E-mail: [email protected]

Figure 1.2 various techniques used to join similar and dissimilar materials Solid state welding processes such as friction welding, ultrasonic welding, cold rolling, explosive welding, diffusion welding and friction stir welding are achievable methods by which Al-steel dissimilar materials can be joined together. Meanwhile, in the past few years,

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researchers have focused on friction stir welding (FSW) technology to join Al – steel materials together. FSW is a solid state welding process, invented and patented by The Welding Institute (TWI), London, UK in 1991 [3–9]. It is remarkably simple welding process. Figure 1.3 illustrates schematically FSW processes for two plates placed in butt configuration

Figure 1.3 A schematic drawing of FSW in a butt joint configuration (Mishra and Ma, 2005). A nonconsumable rotating tool having specially designed shoulder, and pin is plunged into the adjoining edges of the plates and moved along the parting line. The frictional heat generated between the rotating tool and the work piece and the heat from adiabatic plastic deformation of the work piece material cause the material around the tool to soften. The forward motion and the rotation of the tool cause the material in this state to move around the tool from the front to the back of the tool. It leads to a joint formation between the two plates. Different terminologies used in FSW are also labeled in the schematic shown in Figure 1.3[1]. This paper broadly reviews recent work along with some significant aspects of dissimilar Al- steel FSW system such as process parameters and its effect, material flow and microstructure changes, defects, mechanical properties and variant of FSW. II.

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tool reactivity, fracture toughness, machinability, uniformity in microstructure and density, availability of materials are required for getting success in the FSW process [5]. Simplest tool design and cost effective tool material are the greatest advantages of dissimilar Al- steel FSW system. Available literatures indicate that the Tungsten Carbide is commonly used as a tool material for dissimilar Al- steel FSW system. Literature summary of different recommended tool materials for dissimilar Alsteel FSW system are shown in Table 1. B. Tool Design and Geometry The FSW tool has two basic parts: (I) Pin and (II) shoulder. Important elements of these parts are shoulder diameter, shoulder surface angle, pin geometry, including its shape and size, and the nature of tool surfaces [10]. Tool design and geometry affects the heat input, force & torque variations and plasticized material flow in FSW technology [6]. Different tool designs and geometries for dissimilar Al – steel FSW system are discussed as below. K.K. Ramachandran et al 2015 studied the effect of Tool Axis Offset and Geometry of Tool Pin Profile on the Characteristics of Friction Stir Welded Dissimilar Joints of Aluminium Alloy AA5052 and HSLA Steel [11] using a compound tools WC pin and shoulder and oil hardened EN31 steel shank which is shown in figure 2.1 and various tool geometries as shown in figure 2.2.

Figure 2.1 FSW compound tool ( K.K. Ramachandran et al 2015).

FSW TOOL

FSW tool is a heart of the process. The functions of the FSW tool are heating and softening of base materials, extruding the base materials from front to back and from top to bottom of the tool, and finally make the bonding of the softened material to form a solid state joint [10]. The tool material and tool geometry are the important components of FSW tool [32]. A. Tool Material Tool material must be such that, the geometry and features continue unaffected during the process. Prerequisite of tool material is critical for higher melting work piece materials. Significant characteristics of tool material such as ambient and elevated temperature strength, elevated temperature stability, wear resistance,

Fig. 2.2.Experimented FSW tool pin profiles (K.K. Ramachandran et al 2015)

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C. Tool Shoulder In FSW, the shoulder diameter is maximum responsible for heat generation. It has been found that the shoulder generates around 87% heat by rubbing action between the Shoulder surface and the work piece [8][32]. Tool shoulder diameter and geometry/surface features affect the quality of weld in FSW as it contributes to maximum heat generation. For achieving good quality FSW joint, the optimum shoulder diameter is one of the important parameters needed into consideration before the welding [4]. Tool shoulder diameter affects the peak temperature variation, material deformation, plunge load variation, mechanical properties, microstructural variation and formation of intermetallic compounds (IMCs) in dissimilar Al -Steel FSW system. H. A. Derazkola et al 2015 et al. [12] claimed that uniform mixing between AA1100 and A441 AISI with a proper material flow pattern can be obtained with 20 mm diameter. Maximum tensile strength 90% of base metal was reported. D. Tool Pin Tool pin is responsible for plasticized material flow by stirring action in the joint area. Pin diameter, surface profile and pin length are important parts of the tool pin. Pin length affects the penetration level of plasticized material in nugget/ stir zone. Tool pin length is generally kept 0.2 to 0.3 mm less than the work piece thickness so that the shoulder can get proper contact with the work piece by giving appropriate axial plunge load [4]. Pin diameter and surface profile features affect the size of stir zone, microstructure and material flow. The relation between pin and shoulder dimension is defined as shoulder to pin diameter ratio (SPR)[32].

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offset is nothing but the displacement of FSW tool towards particular base material[32]. K.K. Ramachandran et al 2015 produced the best joint at a tool axis offset of 2 mm towards the Al alloy.

Fig. 3.1. Schematics of tool axis offset used for tool T1 (K.K. Ramachandran et al 2015) H. A. Derazkola et al 2015 studied the “ Analysis of process parameters effects on dissimilar friction stir welding of AA1100 and A441 AISI steel” with tool offset 1.3 mm and concluded the heat generated and the plasticized Aluminium flow in the 0.8 mm offset were not appropriate. On the other hand, at offset w1.3 mm, smaller volume of pin tool was placed in the steel side, and subsequently, the tool did not enable the deformation of the steel. Figure3.2 shows the effect of tool offset on joint Effiency.

A. Yazdipour A. and Heidarzade studied Effect of friction stir welding on microstructure and mechanical properties of dissimilar Al 5083-H321 and 316L stainless steel alloy joints [13] using simple cylindrical pin and reported the 238 Mpa joint strength. III.

PROCESS PARAMETERS

In FSW technology, the important process parameters are rotational speed, welding speed or tool traverse speed, axial plunge load and tool tilt angle for similar material system. Other two parameters such as tool pin offset and position of different base materials in fixture are the additional parameters which affect the dissimilar FSW system along with mentioned similar material system’s parameters[32]. Importance of these parameters are explained next in detail. A. Tool pin offset or Tool Axis offset Tool pin offset is the key parameter as far as the dissimilar Al –Steel FSW system is concerned. Tool pin

Figure 3.2 . Effects of tool offset on joint efficacy (welded samples by 800 rev min-1, 63 mm min-1, tool tilt angle 20 and plunge depth 0.2 mm) (H. A. Derazkola et al 2015)

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Table 1: Summary on the used parameters and joint strength of FSW (Al-to-steel)[33]. Metallic alloys to be joined

Thick ness of alumi nium alloy ta

Thic knes s of steel ts

Tool Material

Diame ter of the shoul der Ds

Diame ter of the Pin Dp

Pin Shape

Tool rotatio nal Speed (N) rpm

Tool Translati onal speed (V) mm/min

Too l Tilt An gle α(0 )

Effien cy (UTS)

Refere nce

A441 AISI

3

3

tungsten carbide

20

4–6

Pin length 3.4 mm

800

63

1, 2 and 3

[12]

AA5 052

HSLA Steel (IRSM4 2-93)

3

3

4

TC SC 2.7 pin length

500

45

1.5

Al 5083H321 6061T6

316L stainless steel Q235 steel

5

5

compoun d tools WC pin and shoulder and oil hardened EN31 steel shank H13 steel

90% of base metal 188 MPa (join9 1%)

20

5

simple cylindri cal

280

160

2.5°

238 MPa

[13]

3

3

20

6

950

23.5mm/ min

196M Pa

[15]

6061

AISI 1018

6

6

tungsten and molybde num tool steel H13

25

5.5

914

140

[10]

5083

SS400

tool steel SKH57

15

2

AA10 50 H16 alumi nium 6056

ASTM A284 steel

20

6.5

38.6% – (117 MPa) /w = 559 N/mm -(186 MPa 59% (81 MPa)

304

4

4

800

80

6013T4

X5CrNi1 8-10 stainless steel

4

4

800

80

7075T6

mild steel

3

3

500

100

Al alloy AA1 100

steel

2

2

12

225

unthrea ded cylindri cal

4

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900

43.8

1

20 or 100

[11]

[25]

[17]

[16] 1

Fatigu e Strengt h efficie ncy is 70% (333 MPa)

[14]

[26]


Al with 5% Si (AlSi)

Low carbon steel (Europea n grade: DC01) HC260L A HSS DP600

2

2

1.5

1.5

mild steel (St52) stainless steel 304

3

3

3

3

tungsten carbide

15

pure Al

IF steel

3

3

6082

mild steel

6

6

tungsten carbide pin, high speed steel shoulder AISI 4140 tool steel tungsten carbide with 10% cobalt content

6181T4

5186

6061

6061 T651 1

TRIP 780/800 steel

1.5

1.4

Al– Mg alloy

A316L stainless steel

∼4

∼4

Tungsten – Rhenium WRe25

13

Conica l Dr= 6.5

400

300

13

5

1600

480

94

77% (115 MPa)

[18]

[19] 74%

18

M3

355

56

3.5

710

30

3

25

Conica l Dr =5,Dt =2.5

600

100

2.5

25

6

300

5

2

12.7

Conica l Dt=2.5

1800

90

3

250

16, 20, and 25

3

15

The literature indicated that 0.4 mm to 1.3 mm pin offset is preferred to achieve good quality dissimilar AlSteel FSW joint (refer Table 1). However, the optimum tool pin offset is depends on the tool design and thickness of the work piece to be welded. B. Position of Al and Steel Base Materials Position of base material does not consider in the similar material FSW system, but it is an important affecting parameter for dissimilar Al- Steel FSW system. The butt joint and lap joint configurations are affected by this parameter. Material flow in the joint area is strongly affected by advancing and retreating sides [5]. Generally Steel plates were located on advancing side. According to Watanabe et al. [14], steel plate is supposed to be placed in the advancing side of the tool as shown in figure 3.3. According to the Nune’s kinematic model, the way of material flows of retreating side is straight through current flow while it follows the whirlpool pattern at advancing side (explained very well by Mishra et al. ). So, by keeping Steel on advancing side, the flow path of Steel particles can be improved through a whirlpool pattern that

4

threade d

90% (245 MPa) ≈63% (≈254 MPa) 86% (123 MPa)

[27]

/(160 MPa) 85% (240 MPa)

[23]

90 %

[28]

[21]

[22]

[24]

subsequently provides uniform distribution of Fe particles in Al matrix which leads to make sound bonding. Also, the harder material (i.e. Steel) is difficult move from retreating to advancing side which results in non-uniform material flow, if the Steel is placed at retreating side.

Fig. 3.3. Schematic illustration of a rotating pin position in this study: (a) bird’s eye schematic view of the method and (b) schematic view of the cross-section perpendicular to weld line. [14]

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C. Rotational Speed The speed at which the FSW tool rotates is called rotational speed or tool speed. H. A. Derazkola et al 2015 studied the effect of tool rotational speed varying from 500,630,700 and 800 rpm respectively. And concluded that with the increase in rotational speed, the thickness of intermetallic compounds that were formed in the material interface increases and the joint microhardness increases. From the table.1 it can be concluded that high rotational speed is required for the sound joint efficiency and rotational speed around 800 to 900 rpm is preferred. If lesser rotational speed are used the higher travel speed of the tool is to be maintained for the good joint strength

Figure 3.5. Surface material flow at different traverse speed: a 25 mm min-1; b 40 mm min-1; c 63 mm min-1; d 80 mm min-1 (800 rev min-1, 28 tilt angle, 0.2 mm plunge depth and 1.3 mm tool offset) . (H. A. Derazkola et al 2015)

Figure 3.4. Effects of tool rotational and traverse speed on peak temperature (0.2 mm plunge depth, tool offset of 1.3 mm and 28 tilt angle).(H. A. Derazkola et al 2015) D. Welding Speed or Travel Speed Welding speed or travel speed is the speed at which tool travel through the joint line of work piece[32]. Welding speed is equally important for achieving good quality dissimilar Al –Steel FSW system. With increasing heat abate, steel resists against aluminium pressure; hence, tiny voids and surface interstice are as shown in Figure 3.5

E. Tool Tilt Angle Tool tilt angle is defined as “the angle at which the FSW tool is positioned relative to the work piece surface, i.e. no or 0˚ tilted tool is positioned perpendicular to the work piece surface” [11]. According to [31] [33] larger tilt angle of 2.50 and 30 and have achieved high joint Effiency of 238 MPa which is clearly seen in the Table 1.

F. Downward Force or Plunge Force or Axial Force Force acts parallel to the spindle axis direction are called downward force or plunge force or axial force. Plunge force helps to maintain the contact of the tool at or beneath the material. Sufficient plunge force is required to achieve full penetration in the stir zone. Insufficient plunge force gives an inappropriate vertical flow of deformed material, whereas higher plunge force causes thinning of the deformed material and results in a flashout effect[32]. IV.

MICROSTRUCTURES AND INTERMETALLIC COMPOUNDS

Microstructures of similar materials FSW system are divided into four parts; area under the shoulder consists of two microstructures (stir zone and thermo-mechanically affected zone) while outside of shoulder heat affected zone and parent metal microstructure. Same way, the dissimilar materials FSW system consists of these zones. These different microstructures subsequently affect the mechanical properties. The microstructure of Al-tosteel dissimilar weld is investigates at the stir zone (SZ), thermo-mechanically affected zone (TMAZ), heataffected zone (HAZ) and the base material (BM)[32]. According to H. A. Derazkola et al 2015 intermetallic compounds are formed during dynamic recrystallisation that causes increasing in microhardness.K.K. Ramachandran et al 2015 studied that specimen produced using tool T3, the fracture is a blend of brittle and ductile

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mechanisms.Xinjiang Fei et al reported Hybrid FSW using Laser power is 800W 0.8 mm offset that narrow inter-metallic compounds layer with average thickness of about 4μm [15]

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system due to imbalances in properties of work piece materials. Tensile properties and hardness results for different, dissimilar Al - Steel FSW systems are summarized in Table 1. Hardness across the weld section typically observed “W” shaped profile for similar FSW systems [5]. It is reported that the ultimate tensile strength (UTS) of dissimilar Al - Steel FSW system is mostly less than the base materials. According to R Raffei et al 2016, theAA5083-A316 bi-metallic joint prepared at the welding condition with this criticalheatinput value(traverse velocityof16mm/min) provided the maximum joint strength and failed from the AA5083 base material and the parameters affecting the process heat input must be accurately controlled in order to obtain a joint with a maximum strength[28]. VI.

Fig. 4.1. Optical micrographs at the joint interface at positions of tool axis offset corresponding tohighest UTS for (a) tool T1 (b) tool T2 (c) tool T3 (d) tool T4 (K.K. Ramachandran et al 2015)

Fig. 4.2. SEM images at the joint interface at positions of tool axis offset corresponding to highest UTS for tool T1(K.K. Ramachandran et al 2015) V.

MECHANICAL PROPERTIES OF DISSIMILAR AL – STEEL FSW SYSTEM

WELDING DEFECTS OF DISSIMILAR AL - STEEL FSW SYSTEM

The dissimilar Al – Steel FSW defects can be caused by several incorrect process parameters such as tool design, rotational speed, welding speed, plunge depth, tilt angle, tool pin offset and fixed position of the base metals. Additionally, a too wide welding gap and mismatch of work piece plate thickness can also lead to the formation of welding defects[32]. Utmost common welding defects occurred in dissimilar Al – Steel FSW systems are presented in Fig. 6.

Fig. 6 .Macrostructure of welded samples by 710 rev min -1, 40 mm min -1, tool tilt angle 28, 1.3 mm tool offset and a 0.1 mm, b 0.2 mm, c 0.3 mm and d 0.4 mm tool plunge depth

Mechanical properties of dissimilar Al - Steel FSW joint are quite different than the similar materials FSW

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VII.

VARIANTS OF FSW FOR DISSIMILAR AL – STEEL MATERIALS

Modern innovative progresses of FSW technology for dissimilar Al- Steel system are discussed here as variants of the technology. Some of the variants are friction stir lap welding FSLW. In FSLW, pin plunging of steel plate is very important [31]. Though, the pin is not reaching the plate surface or penetrates through, joint can be produced Merkleinand Giera, presented a tailored hybrid welding method by adapting the spot laser assistance that preheated the steel ahead of the FSW tool. This technique can enhance the deformation of the steel plate and minimize wear of tool. The resulting joint efficiency of AA6016-T4 to DC04 steel FSBW can reach 80% of the aluminum base alloy. The results showed that welding speed increment to 2000 mm/min can demonstrate high weld formability. Ming-jer Hseih et al 2016 performed friction stir spot fusion welding(FSSW) of low carbon steel to aluminum alloy using assembly embedded rod(AER) tool under the downward force of 12 KN and rotational speed of 1200 rpm at different dwell times. The Al alloy sheet was melted atb the central area of the faying surface, so that two IMC layers were formed at this surface and identified as Fe2Al5 and Fe4Al13, as detected by XRD and SEM images. The IMC thickness increased along with dwell time, but its increment rate became slower for IMC thickness larger than 25mm [29] C. Leitao et al performed dissimilar friction stir lap welding (FSLW) of Aluminium to steel by using a multipass welding strategy for increasing the bonding area.[30] VIII.

CONCLUSIONS AND SUMMARY

preferred properties can be attained. Nevertheless, different variants such as are friction stir lap welding FSLW, friction stir spot fusion welding (FSSW) have been engaged to improve the properties of this system. Nonetheless, growth in these processes can be considered as a vigorous area for research. In addition to this, there is a lack of complete data of tool design and tool material for different thicknesses and alloys of this system. It is also reported that, most of the work for this system is on characterization and properties of the joint. On the other hand, it is necessary to develop specific industrial applications of dissimilar Al to Steel joint welded by FSW technology. ACKNOWLEDGMENT The Authors would like to express their appreciation to the Director and all the staff of Mechanical Engineering department of NIT Manipur for their support and motivation. REFERENCES [1]

[2]

[3]

[4]

[5] [6]

The prominent features of dissimilar materials Al to Steel FSW system have been briefed. The effect of different process parameters on the properties of dissimilar materials are also deliberated in detail. In addition to this, microstructures, welding defects and variants of FSW for dissimilar system of Al to steel materials have been gauged. It can be noted that, dissimilar joining of Al to Steel by FSW is still not extensively engaged because of low mechanical properties and formation of IMCs in large amount. Inadequacies such as fragmental defects, voids, pores and cracks are commonly found in dissimilar Al to Steel FSW system which are formed due to improper process parameters that consequently forms different IMCs and lead to the low mechanical properties. These IMCs also increases the hardness of joint area and that also results the joint area brittle which is powerful parameter for brittle fracture and low elongation. There is no analytical relation for optimum process parameters through which

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[12]

[13]

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[32] Kush P. Mehta & Vishvesh J. Badheka (2015): A Review on Dissimilar Friction Stir Welding of Copper to Aluminum: Process, Properties and Variants, Materials and Manufacturing Processes, DOI: 10.1080/10426914.2015.1025971” [33] Sadiq Aziz Hussein, Abd Salam Hadzley, Characteristics of Aluminum-to-Steel Joint Made by Friction Stir Welding: A Review, Materials Today Communications http://dx.doi.org/10.1016/j.mtcomm.2015.09.004

Sameer MD. Pursuing PhD in the Department of mechanical Engineering in NIT Manipur, India. He is from the state of Telangana. He completed his MTech in JNTUHCEH, Kukatpally, Hyderabad. His research interest are Friction stir welding, casting and Electric discharge machining. He is working in CJITS, Jangaon as an Assistant Professor in Department of Mechanical Engineering since 2010. ([email protected])

ISBN 978-93-86176-46-2