Extrinsic-Riveting Friction Stir Lap Welding of Al/Steel Dissimilar Materials

Author:

Meng Xiangchen12ORCID,Gao Jiaze1,Xie Yuming12,Huang Tifang1,Dong Jihong3,Ma Xiaotian2,Wang Naijie2,Huang Yongxian12ORCID

Affiliation:

1. State Key Laboratory of Precision Welding & Joining of Materials and Structures, Harbin Institute of Technology, Harbin 150001, China

2. Zhengzhou Research Institute, Harbin Institute of Technology, Zhengzhou 450046, China

3. AVIC Manufacturing Technology Institute, Beijing 100024, China

Abstract

To obtain high-quality joints of Al/steel dissimilar materials, a new extrinsic-riveting friction stir lap welding (ERFSLW) method was proposed combining the synthesis advantages of mechanical riveting and metallurgical bonding. SiC-reinforced Al matrix composite bars were placed in the prefabricated holes in Al sheets and steel sheets, arranged in a zigzag array. The bars were stirred and mixed with Al sheets under severe plastic deformation (SPD), forming composite rivets to strengthen the mechanical joining. SiC particles were uniformly dispersed in the lower part of the welding nugget zone (WNZ). The smooth transition between the SiC mixed zone and extrinsic-riveting zone (ERZ) ensured the metallurgical bonding. The maximum tensile shear load of the joints reached 7.8 kN and the maximum load of the weld per unit length was 497 N/mm. The fracture occurred at the interface between the rivets and steel sheets rather than the conventional Al/steel joining interface. Moreover, ERFSLW can prolong the service life of joints due to three fracture stages. This method can be further extended to the welding of other dissimilar materials that conform to the model of “soft/hard”.

Funder

National Natural Science Foundation of China

Special Fund for Research on National Major Research Instruments

National Key R&D Program of China

Publisher

MDPI AG

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