What is it about?

Optimization of the intermetallic layer thickness and the suppression of interfacial defects are key elements to improve the load bearing capacity of dissimilar joints. However, till date we do not have a systematic tool to investigate the dissimilar joints and the intermetallic properties produced by a welding condition. Friction Melt Bonding (FMB) is a recently developed technique for joining dissimilar metals that also does not exempt to these challenges. The FMB of DP980 and Al6061-T6 was investigated using a new physical simulation tool, based on Gleeble thermo-mechanical simulator, to understand the effect of individual parameter on the intermetallic formation. The proposed method demonstrates its capability in reproducing the intermetallic characteristics, including the thickness of intermetallic bonding layer, the morphology and texture of its constituents (Fe2Al5 and Fe4Al13), as well as their nanohardness and reduced modulus. The advantages of physical simulation tool can enable novel developing routes for the development of dissimilar metal joining processes and facilitate to reach the requiring load bearing capacity of the joints.

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Why is it important?

fabrication of dissimilar joints are challenging due to the formation of intermetallics. During real manufacturing processes, they have multiple process parameters and they are interconnected. Therefore, it is important to uncouple the physical parameters to understand the development of intermetallic growth. This will help to tackle some challenges in the fabrication of dissimilar joints!


During a welding process [here we use friction melt bonding (FMB)], we have many physical quantities (pressure, temperature, shear forces etc.). Those parameters cannot be controlled independently. Therefore, it is difficult to understand the influence of various physical quantities on the weld formation during the process. Moreover, FMB brings some hot tear defects, this need to tackled systematically. Therefore, in order to simplify the system and to control each parameter, it's crucial to have a good experimental setup that reproduces the processing conditions. for this propose, a physical simulation setup is very helpful.

Curtin University, Curtin Corrosion Centre, Faculty of Science and Engineering

Read the Original

This page is a summary of: A new physical simulation tool to predict the interface of dissimilar aluminum to steel welds performed by friction melt bonding, Journal of Material Science and Technology, May 2019, Elsevier, DOI: 10.1016/j.jmst.2019.05.004.
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