Modelling and control of thermal cycles during dissimilar Friction Melt Bonding of Al6061 to Ultra-Low-Carbon Steel and their role in hot tearing
(2015) EUROMAT 2015 — Location: Warsaw, Poland (20.September.2015)
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- Abstract
- Friction Melt Bonding (FMB) is a novel technique that has successfully been applied to weld aluminium to steel in a lap joint configuration [1]. In this process, a rotating cylindrical tool is pressed and displaced over the steel plate surface generating heat by friction. The heat is transmitted through the thickness of the steel to the aluminium plate placed underneath. The Al plate partially melts at the interface while the steel remains solid. As a result, bonding is achieved by the formation of a thin Fe/Al intermetallic layer. FMB tests performed with Al6061 welded to ULC steel have shown that for high tool speeds -200 mm.min-1 and over- welding defects in the form of hot tears are likely to arise. In this framework, the hot tearing susceptibility of FMBed Al6061 has been tested and analysed with the help of a model accounting for the cooling and strain rates during the solidification of the molten pool. A simple uncoupled thermomechanical model of FMB has been used to estimate the thermal fields. The validation is carried out through temperature measurements, tool torque measurements and observations of the resulting microstructure for different welding conditions. The critical thermomechanical conditions for the deployment of hot tearing are finally assessed by comparison with 3D X-ray tomography observations. In a later stage, to overcome hot tearing under unfavourable welding parameters, a filler material is tested. Placed between the Al6061 and the steel, the performance of the filler material is evaluated for different welding conditions.
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Citations
Jimenez Mena, N., Simar, A., & Jacques, P. (2015). Modelling and control of thermal cycles during dissimilar Friction Melt Bonding of Al6061 to Ultra-Low-Carbon Steel and their role in hot tearing. EUROMAT 2015, Warsaw, Poland. https://hdl.handle.net/2078.5/45923