10/04 COVER 1 zaida

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Specifications	10/04 COVER 1 zaida
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WELDING RESEARCH -S277WELDING JOURNAL ABSTRACT. The authors tried to butt- joint weld an aluminum alloy plate to a mild steel

Specifications	10/04 COVER 1 zaida
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Content	WELDING RESEARCH -S277WELDING JOURNAL ABSTRACT. The authors tried to butt- joint weld an aluminum alloy plate to a mild steel plate using friction stir welding. This study investigated the effects of pin rotation speed, position of the pin axis, and pin diameter on the tensile strength and microstructure of the joint. The main results obtained are as follows: Butt-joint welding of an aluminum alloy plate to a steel plate was easily and successfully achieved. The maximum ten- sile strength of the joint was about 86% of that of the aluminum alloy base metal. Many fragments of the steel were scat- tered in the aluminum alloy matrix, and fracture tended to occur along the inter- face between the fragment and the alu- minum matrix. A small amount of inter- metallic compounds was formed at the upper part of the steel/aluminum inter- face, while no intermetallic compounds were observed in the middle and bottom regions of the interface. A small amount of intermetallic compound was also often formed at the interface between the steel fragments and the aluminum matrix. The regions where the intermetallic com- pounds formed seem to be fracture paths in a joint. Introduction Energy savings and environmental preservation are important issues for us to resolve. Since reducing the weight of ve- hicles is one of the efficient measures, the use of the combination of steel and alu- minum alloy has been increasing in fabri- cating vehicles. Under this situation, many trials to weld steel to aluminum alloy have been conducted. However, sound joints have not been produced so far, because hard and brittle intermetallic compounds were formed at the weld whenever steel was welded to aluminum by fusion welding. At present, the following methods have been employed to produce a joint be- tween steel and aluminum. One method utilizes a transition joint that consists of a steel plate welded in advance to an alu- minum alloy plate by explosive bonding or rolling (Ref. 1). Others are solid-phase bonding methods, such as friction welding (Ref. 2), ultrasonic joining (Ref. 3), and rolling (Ref. 4). The method using the transition joint, however, involves some difficulties in that the transition joint is not easy to produce and is expensive, and the joint is limited in shape. Rotary friction welding has the dif- ficulty that at least one material to be joined should be circular in cross-sec- tional shape. Ultrasonic welding and rolling also have the shortcoming that they are applicable only to thin plate. A new method has been tried in which the heat conduction from a steel plate heated by a laser beam melts the faying surface of an aluminum plate, resulting in welding the steel to the aluminum by the molten aluminum (Ref. 5). However, this method presents difficulties in that some brittle intermetallic compound is still formed and it is hard to control the heat input and the melting amount of the alu- minum by laser irradiation. In addition, laser equipment is expensive. Recently, a few preliminary studies have been reported on friction stir weld- ing (FSW) — a process developed by TWI (Ref. 6) — of aluminum to steel butt joints (Ref. 7) and lap joints (Ref. 8). In this paper, the authors applied FSW to produce a butt joint between aluminum alloy and steel, and are reporting the de- tails of the joint performance. Explanation of the Rotating Pin Position in the Friction Stir Welding Employed in this Study Figure 1 is a schematic illustration to explain pin position in friction stir weld- ing. Figure 1A is a bird’s-eye view of the method, and B is a view of the cross sec- tion perpendicular to a weld interface. A rotating pin is plunged into the alu- minum as shown in the figure. Next, the rotating pin is pushed toward the faying surface of the steel and, consequently, the oxide film is mechanically removed from the faying surface by the rubbing motion of the rotating pin. Aluminum, which is in a fluid-like plastic state due to the heat generated by the friction of the rotating tool shoulder, adheres to the activated faying surface of the steel, so that joining between steel and aluminum is achieved. In this process, since the rotating pin is plunged into the softer aluminum and does not come in contact with the steel, the rotating pin shows minimal wear. Welding by FSW is ordinarily com- pleted through stirring by a rotating pin inserted around the center of the weld in- terface of butted base plates. A prelimi- nary experiment proved that when the ro- tating pin was inserted around the center of the weld interface between the steel plate and the aluminum alloy plate, weld- ing could not be achieved because of ex- cessive wear of the rotating pin in a short duration. The wear caused insufficient stirring between the aluminum alloy and the steel. This point will be referred to later. Experimental Materials and Welding Conditions Plates of 2-mm-thick SS400 mild steel (hereafter, Fe) and A5083 (Al-0.5 Mg-0.5 Mn wt-%) aluminum alloy (hereafter, Al) were welded. The ultimate tensile strength of the A5083 base metal was about 275 MPa and that of the SS400 was about 455 MPa. The shape and dimension of both plates was rectangular and 140 mm in length and 40 Friction Stir Welding of Aluminum Alloy to Steel Aluminum alloy plate was successfully butt-joint welded to steel plate by friction stir welding K. KIMAPONG ANDT. WATANABE K. KIMAPONG and T. WATANABE are with the Dept. of Mechanical Engineering, Niigata Univer- sity, Niigata, Japan. KEYWORDS Joining of Dissimilar Metals Friction Stir Welding Steel Aluminum Alloy Tensile Strength of a Joint Kimapong Supp for 10/04corr 8/25/04 3:33 PM Page 277
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