For the prevention of global warming, reduction of CO2 emission is strongly required for vehicle. The fuel consumption regulation around the world becomes hard year by year. Concurrently, electrification of vehicle increases the weight of electrical system. Thus, the weight reduction is necessary for vehicle. Lightweight vehicle can be realized by placing the right material for the right place by means of multi-materials design. Thus, it is necessary to develop the multi-material joining technology. Especially, dissimilar metal welding between aluminum and steel is important to fabricate light weight and high strength for safety at low cost. Conventional fusion welding is difficult to fabricate sound joint due to generation of fragile intermetallic compound (IMC) layer in the weld interface. On the other hand, friction stir welding (FSW) is possible to fabricate high strength dissimilar metal weld due to solid state welding. In FSW, control of material flow during welding is important to fabricate sound weld. Although the material flow is controlled by the welding tool shape and the behavior (i.e. rotation speed, welding speed, etc), it is difficult to see the material flow directly. Thus, it is necessary to understand and control the material flow during FSW for effective welding. In this study, material flow during FSW between aluminum and steel was elucidated by thermal fluid analysis and simulation experiment with high-speed camera observation. Based on this material flow analysis, several shapes of welding tool were tested for control of material flow during FSW.


Control of Material Flow During Friction Stir Welding Between Aluminum and Steel by Welding Tool Shape

Division / Sponsor: 
Manufacturing Engineering Division (MED)

International Manufacturing Science and Engineering Conference - Paper Proceedings: https://asmedigitalcollection.asme.org/MSEC/MSEC2020/volume/84256

JSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing - Paper Proceedings: https://asmedigitalcollection.asme.org/lemp/LEMP2020/volume/83624

MSEC2020 - Virtual Conference, LEMP2020 - Virtual Conference

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