Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties
This study investigated the effect of the friction stir welding rotation rate and welding speed on the quality and properties of the dissimilar joints between aluminum and carbon steel. Plates of 4 mm thickness from both AA2024 and AISI 1018 were successfully friction stir butt welded at rotation sp...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-02-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/11/2/330 |
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| author | Mohamed M. Z. Ahmed Nabil Jouini Bandar Alzahrani Mohamed M. El-Sayed Seleman Mohammad Jhaheen |
| author_facet | Mohamed M. Z. Ahmed Nabil Jouini Bandar Alzahrani Mohamed M. El-Sayed Seleman Mohammad Jhaheen |
| author_sort | Mohamed M. Z. Ahmed |
| collection | DOAJ |
| description | This study investigated the effect of the friction stir welding rotation rate and welding speed on the quality and properties of the dissimilar joints between aluminum and carbon steel. Plates of 4 mm thickness from both AA2024 and AISI 1018 were successfully friction stir butt welded at rotation speeds of 200, 250, and 300 rpm and welding speeds of 25, 50, and 75 mm/min. The joint quality was investigated along the top surface and the transverse cross-sections. Further investigation using scanning electron microscopy was conducted to assess the intermetallic layers and the grain refining in the stir zone. The mechanical properties were investigated using tensile testing for two samples for each weld that wire cut perpendicular to the welding direction and the hardness profiles were obtained along the transverse cross-section. Both the top surface and the transverse cross-section macrographs indicated defect free joints at a rotation rate of 250 rpm with the different welding speeds. The intermetallic compounds (IMCs) formation was significantly affected by the heat input, where there is no formation of IMCs at the Al/steel interfaces when higher traverse speed (75 mm/min) or lower rotation speed (200 rpm) were used, which gave the maximum tensile strength of about 230 MPa at the low rotation speed (200 rpm) along with 3.2% elongation. This is attributed to the low amount of heat input (22.32 J/mm) experienced. At the low traverse speed (25 mm/min and 250 rpm), a continuous layer of Al-rich IMCs FeAl<sub>3</sub> is formed at the joint interface due to the high heat input experienced (79.5 J/mm). The formation of the IMCs facilitates fracture and reduced the tensile strength of the joint to about 98 MPa. The fracture mechanism was found to be of mixed mode and characterized by a cleavage pattern and dimples. The hardness profiles indicated a reduction in the hardness at the aluminum side and an increase at the steel side. |
| first_indexed | 2024-03-09T00:52:59Z |
| format | Article |
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| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-09T00:52:59Z |
| publishDate | 2021-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-d66439d0561049829693c2b39671f4422023-12-11T17:04:59ZengMDPI AGMetals2075-47012021-02-0111233010.3390/met11020330Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical PropertiesMohamed M. Z. Ahmed0Nabil Jouini1Bandar Alzahrani2Mohamed M. El-Sayed Seleman3Mohammad Jhaheen4Mechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 16273, Saudi ArabiaMechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 16273, Saudi ArabiaMechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 16273, Saudi ArabiaDepartment of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, EgyptDepartment of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, EgyptThis study investigated the effect of the friction stir welding rotation rate and welding speed on the quality and properties of the dissimilar joints between aluminum and carbon steel. Plates of 4 mm thickness from both AA2024 and AISI 1018 were successfully friction stir butt welded at rotation speeds of 200, 250, and 300 rpm and welding speeds of 25, 50, and 75 mm/min. The joint quality was investigated along the top surface and the transverse cross-sections. Further investigation using scanning electron microscopy was conducted to assess the intermetallic layers and the grain refining in the stir zone. The mechanical properties were investigated using tensile testing for two samples for each weld that wire cut perpendicular to the welding direction and the hardness profiles were obtained along the transverse cross-section. Both the top surface and the transverse cross-section macrographs indicated defect free joints at a rotation rate of 250 rpm with the different welding speeds. The intermetallic compounds (IMCs) formation was significantly affected by the heat input, where there is no formation of IMCs at the Al/steel interfaces when higher traverse speed (75 mm/min) or lower rotation speed (200 rpm) were used, which gave the maximum tensile strength of about 230 MPa at the low rotation speed (200 rpm) along with 3.2% elongation. This is attributed to the low amount of heat input (22.32 J/mm) experienced. At the low traverse speed (25 mm/min and 250 rpm), a continuous layer of Al-rich IMCs FeAl<sub>3</sub> is formed at the joint interface due to the high heat input experienced (79.5 J/mm). The formation of the IMCs facilitates fracture and reduced the tensile strength of the joint to about 98 MPa. The fracture mechanism was found to be of mixed mode and characterized by a cleavage pattern and dimples. The hardness profiles indicated a reduction in the hardness at the aluminum side and an increase at the steel side.https://www.mdpi.com/2075-4701/11/2/330dissimilar friction stir weldingAA2024aluminum alloyAISI 1018microstructure evaluationmechanical properties |
| spellingShingle | Mohamed M. Z. Ahmed Nabil Jouini Bandar Alzahrani Mohamed M. El-Sayed Seleman Mohammad Jhaheen Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties Metals dissimilar friction stir welding AA2024 aluminum alloy AISI 1018 microstructure evaluation mechanical properties |
| title | Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties |
| title_full | Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties |
| title_fullStr | Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties |
| title_full_unstemmed | Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties |
| title_short | Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties |
| title_sort | dissimilar friction stir welding of aa2024 and aisi 1018 microstructure and mechanical properties |
| topic | dissimilar friction stir welding AA2024 aluminum alloy AISI 1018 microstructure evaluation mechanical properties |
| url | https://www.mdpi.com/2075-4701/11/2/330 |
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