Feasibility study on aluminum alloys and A۴۴۱ AISI steel joints by friction stir welding

In this paper, welding feasibility between AA۱۱۰۰, AA۵۰۵۰ and AA۶۰۸۲ aluminum alloys and A۴۴۱ AISI steel by friction stir welding has been studied. Mathematical analysis of the heat generation during process showed that the maximum temperature produced in AA۶۰۸۲ aluminum alloy and A۴۴۱ AISI joint but heat distribution in AA۱۱۰۰ aluminum alloy was higher than the other alloys. The investigation on joints windows concluded that the connecting link between AA۱۱۰۰ and A۴۴۱ AISI steel was without any defect. Because of improper heat production and distribution in other joints, small tunnel was formed in the joints lower zones. Due to the softness of aluminums rather than steels, in tensile tests all joints were broken from the aluminum base metals. Strongest weld belonged to AA۵۰۵۰ aluminum alloy and A۴۴۱ AISI steel joint that was about ۸۴% of the aluminum base metal strength. Maximum joint efficacy based on A۴۴۱ AISI has its place to AA۶۰۸۲ to A۴۴۱ weld. Microhardness tests shows that welding line between AA۱۱۰۰ aluminum alloy and A۴۴۱ AISI steel is harder that other joints.