Joining of 1100 Al Alloy to AISI 1045 Carbon Steel by Friction Stir Welding

Abstract

Joining of dissimilar materials like Al alloy to carbon steel is attractive for industrial applications such as automotive industry. In this research, Friction Stir Welding (FSW) has been used to joint between dissimilar materials like 1100 Al alloys to AISI 1045 carbon steel. In this paper, the effect of rotational speed, feedrate and offset of tool are investigated on mechanical and metallurgical properties of the welding. The joints were evaluated by mechanical testing and metallurgical analysis. Metallurgical properties carried out by optical microscopy and Scanning Electron Microscopy (SEM) and mechanical properties conducted by the joint strength. Finally, optimum value of tool rotational speed and feedrate were obtained 710 rpm and 28 mm/min respectively and the best offset value of the tool obtained 1.5 mm in the Al alloy. Tensile strength properties of Al1100/1045 carbon steel joints were found to be approximately 20% lower than that of the Al 1100-H14 alloy base metal