Effect of dwelling time and plunge depth on the joint properties of the dissimilar friction stir spot welded aluminum and steel

  • Mahmoud Abdul-Maksoud Metallurgical and Materials Engineering Department, Faculty of Petroleum and Mining Engineering.
  • Professor Mohamed Zaky Mechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, KSA https://orcid.org/0000-0002-9550-7431
  • Professor Mohamed El-Nagar Metallurgical and Materials Engineering Department, Faculty of Petroleum and Mining Engineering. Suez University, Suez 43721, Egypt
  • Associate Professor Adel Mohamed Metallurgical and Materials Engineering Department, Faculty of Petroleum and Mining Engineering. Suez University, Suez 43721, Egypt
DOI: https://doi.org/10.36909/jer.11367

Abstract

A sound joints of a far apart property, pure aluminum and mild steel, dissimilar materials was obtained by the heat input solid state joining process. 2 mm thickness sheets were overlapped and fixed with a fixture device then welded by a friction stir spot welding (FSSW) process. Welding parameters that produced the sound joint were identified. Joints microstructure and mechanical properties were investigated. A microstructural investigation has revealed a creation of mechanical interlocking and discontinuous formation of the intermetallic compounds found at the interface. The IMC thickness ranged from 6 μm to 17 μm with the optimum condition specimen, 800 rpm and 5 Sec dwell time. Tensile–shear test showed that failure load has increased with increasing tool plunge depth and rotational speed. After the optimum value of rotational speed, the shear failure load decreased. The maximum shear failure load of 2.15 KN attained at 800 rpm and 2.4 mm plunge depth. The tool plunge depth in cases of non-penetrating and penetrating in the lower sheet has distinguished joint fracture modes.

Author Biography

Professor Mohamed El-Nagar, Metallurgical and Materials Engineering Department, Faculty of Petroleum and Mining Engineering. Suez University, Suez 43721, Egypt

Metallurgical and Materials Engineering Department, Faculty of Petroleum and Mining Engineering. Suez University, Suez 43721, Egypt

Suez and Sinai Metallurgical and Materials Research Center of Scientific Excellence (SSMMR-CSE), Suez University, 43721 Suez, Egypt

Published
2021-10-27
Issue
Vol 10 No 2B (2022): Journal of Engineering Research
Section
Mechanical Engineering