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TitleFriction Welding of Aluminum Alloy and Carbon Steel Using Insert Met

al

Author(s) Ogawa, Koichi; Ochi, Hiizu; Yasumi, Kaziki; Onishi, Tadakazu

Editor(s)

CitationBulletin of University of Osaka Prefecture. Series A, Engineering and nat

ural sciences. 1995, 43(2), p.113-117

Issue Date 1995-03-31

URL http://hdl.handle.net/10466/8607

Rights

Bulletin of University of Osaka Prefecture

Vol. 43, No. 2, 1994, pp. 113-117 113

Friction Welding

Carbon Steel

of AluminumUsing Insert

AIIoy and

Metal

Koichi OGAwA', Hiizu OcHi'", Kazuk i YASUMI""" and Tadakazu OHNisHi""'

(Received October 30, 1994)

The friction welding of low-weldability 2017 aluminum alloy and S45C carbon steel was conducted

using the insert metals of AI050 industrial pure aluminum and of various aluminum alloys produced

specially for this study. From the tensile tested results of the welded joints, it was clarified that the

aluminum alloys were superior to AI050 aluminum as an insert metal because of the high jointstrength. In particular, the high tensile strength of 380MPa was obtained using the aluminum alloy

composed of 3% magnesium.

1. Introduction

Friction welding has been widely used for welding of

similar or dissimilar metals. However, in friction

welding of dissimilar metals such as aluminum alloy

and steel, it is very difficult to obtain a sound welded

joint because of the formation of brittle intermetallic

compound'). Presently, the demand for friction weld-

ing of such materials is increasing in various industrial

fields. Thus, in order to produce a sound welded joint

between such metals, friction welding was undertaken

using an insert metal2-`). This paper describes the

welding technique of using an insert metal for produc-

ing a sound welded joint of aluminum alloy and steel.

In particular, the effects of various insert metals and

welding conditions on the joint strength were

examined.

Table 1 Chemical compositions of base materia!s (

2. Experimental

The base materials used in this study are 2017-T4

aluminum alloy and S45C carbon steel, while the insert

metals used are 1050-H14 industrial pure aluminum

and aluminum alloy castings consisting of various

elements and pure aluminum. The chemical composi-

tions and mechanical properties are shown in Table 1

and Table 2. The welding material was machined to

the shape and dimensions as shown in Fig. 1.

Friction welding was carried out by the following

procedure with brake-type friction welding. The

welding design used is Shown in Fig. 2. First, S45C

carbon steel and insert metal were welded under the

welding condition of friction pressure R =20MPa,

forging pressure g :130MPa, friction time 4=O.5s,

rotation speed 2V =2500rpm and braking time dg = O.8s.

mass%),

Material si Fe Cu Mn Mg Cr Zn Ti Zr+Ti Al c P s Ni

AI050-H14

A2017-T4

S45C

O.08

O.31

O.26

O.13

O.24

Bal

o.oo

4.0

O.02

o.oo

O.48

O.78

o.oo

O.5

'

o.oo

O.Ol

O.059

o.oo

O.02

m

O.Ol

O.02

-

mO.02-

Bal

Bal

-

ff

･-

O.46

--O.O19

--O.O16

--O.028Table2 Mechanical properties of base

materials.

' Course of Insturument Science, College of Integrated Arts

and Sciences.

"" Joint Research Center, Osaka Institute of Technology.

"' Graduate Student, Department of Metallurgy and Mate-

rials Science, College of Engineering.

"" Departrnent of Metallurgy. and Materials Science, College

of Engineering.

Material Proof Tensile Elongation

stress strength

(HPa) (MPa) (%)

AI050-H14 95 98 32

A2017-T4 248 381 23

S45C 520 670 23

114 Koichi OGAwA, Hiizu OcHr, Kazuki YAsuMi and Tadakazu OHNisHi

g .

'20

80

sus

Fig. 1 Shape and dimensions of weldingmaterial (unit: rnm).

S45C Insert metal A2017

.

5mm Fig. 2 Welding design used.

The tensile strength of the joint welded under the

condition was greater than that of the insert metal.

Then, after the welded insert metal was machined to 5

mm thickness, the insert-metal side was welded to

A2017. The joint strength was examined using the

test specimen without burr in tensile test. The welds

etched by dilute Keller's reagent and nital etchant were

observed by an optical microscope and a scanning

microscope (SEM).

3. Results and discussion

After friction welding of A2017 and S45C was perfor-

med using AI050 insert metal, the welds were inves-

tigatedbyvarioustests. Thetypicalinterfaciallayers

are shown in Fig. 3. When the remaining insert metal

was thick, absent or mixed with A2017 at the welded

interface, the joint strength decreased. On the other

hand, when thin and homogeneous insert metal

remained at the welded interface, the joint strength

increased. That is, insert metal played the role of a

partition between A2017 and S45C, and the joint

strength depended on the strength of the insert metal

used, The changes in tensile strength and total burn-

fit.,,,,

tttltt

i'''

/tH /

..x

-llllll, - .,,11tt,

tlt / tt t/ ttt ltl

' ' tt ' ' ltllttltttt tl

' a B=123. 9MPa

Fig. 3

x

off quantity with the welding conditions are shown in

Figs.4-v7. Theoptimumweldingconditionproducing

maximum joint strength was friction pressure A=

80MPa, forging pressure 4= 180MPa, friction time

4=O.8s, and rotation speed N=4000rpm, and the ten-

sile strength and the total burn-off quantity were

280MPa and 16mm, respectively. The SEM image of

the welded interface and the tensile fractured surface

(S45C side) of joint welded under the optimum welding

condition are shown in Fig. 8. It can be observed from

Fig, 8 that the thin and homogeneous remained insert

metal (20-30#m) remained at the welded interface.

Moreover, partial peel-off between insert metal and

300

Rs.n 20o

e..ESH.iOO

£.

Fig. 4

nEvig

;rr

'vtsg

u?a

8x"ots

s

Friction time ti (s)

Changes in tensile strength and total

burn-off quantity with friction time.

300

Akv. 200b

sge+k"mge..iOO

E

o

S45C+AI050-A20I7

ec=5mm

/o /o o/

'O" de-e-a

Tirne contro1

oXoxo e

o /:r:1?,oxpa

/e ?lf:o.g,rpm

ee/

Ox

23

A g21 v h -ta-,

.tte

19 g

g e B rEl17 :.

o B=156. 0MPa u B=234. 5MPa

Appearance of various interfacial layers (Left side:

A2107, Right side: S45C).

20

Fig. 5

15

40 60 80 100 12e 140

Friction pressure Pi (MPa)

Changes in tensile strength and total

burn-off quantity with friction pres-

sure.

Fbiction Wlalding of Alttmin"m Allay and

G:veb

Bueu

"m2･at8

-

;g.5Cs+.A,1 050-K2017 e/ o

Time eoottJol e/

I,il/×'C..

/

20

A g18 eo

t,'.',.

i6 g.

vi4 St

Eg

12

10

darbon Steel Clsing IZnse,t Meinl

300

200

100

o 150

Fig. 6

180 210 240 270 30e

Forging pressure P2 (MPa)

Changes in tensile strength and total

burn-off quantity with forging pres-

sure.

S45C+AI050-A2017

ec= 5mm

Time contro1 !ot o/o!

1A2017

lAI050

300

200

100

o

o-o x 2>

e/o/

hO- aB -e-b Pl=80MPa

P2=180MPa

t,=O. 8s

t,=O. 8s

.-.-.8.

19

A : v17

ig

it 's15 : g g e13 B

･?e "o ts11

g

I

S45C

Gkweb

sueOk-ve2

･es8

-

/

./e

e/

1

2ooo 3oeo 4ooo sooo Rotation speed N (rpm) Fig. 7 Changes in tensile strength andtetal

burn-off quantity with rotation speed.

S45Coccured. Thepartialpeel-offmeansthattensile

fracture occurs both in the insert metal and at the

interface between the insert metal and S45C.

In the case of using a stronger insert metal, it is

expected that the joint strength increases. To find a

suitable insert metal having higher tensile strength

than AI050 and moreover, which is easily welded to

both A2017 aluminum and S45C carbon steel, various

aluminum alloys were cast, and then welded to both

A2017 and S45C. As a result, aluminum alloys com-

posed of 3% Ni, 3% Zr, 3% Si, 3% Mg, 10% Zn, and

20% Zn were easily welded to both A2017 and S45C.

Figure 9 shows the tensile strength and the total burn-

115

Fig.8 SEM image of the welded interface and tensile fractured surface (S45C side) of welded joint.

off quantity of the joints welded using these alloys.

The welded joint using Al-3% Mg alloy showed the

highest tensile strength among the alloys welded under

the welding condition mentioned above. Since the

changes in total burn-off quantities of all the alloys

was slight, the optimum welding condition alone using

Al-3% Mg alloy was investigated. As shown in Figs.

10rv13, the optimum friction pressure, forging pres-

sure, friction time and rotation speed for producing a

sound weld were 50MPa, 300MPa, O.5s, and 3000rpm

respectively, and the tensile strength and the total

burn-off quantity of the welded joint were 380MPa and

11 mm.

The interfacial layer of the joint welded under the

above optimum welding condition is shown in Fig. 14.

The thickness of the remaining insert metal is about

500"m, which is thicker than AI050. That is, the

strength of the welded joint using Al-3% Mg alloy as

116

400

Koichi OGAwA, Hiizu OcHi, Kazuki YAsuMi and Tadakazu OHNisHi

?k 300:e

gtS 2oo

-ca

.

g 100

o

e

o

Pi=50tva

P2=240}(Pa

t,=O. 8s

N=3000rpe

e

o

oe

-O- a,,

-e- 6

e

o

l5

10

5

3%Ni

Fig. 9

10%dn 3%Ug 3%Sio

Aeevto

b･-ri

:g

:?sA=

'IEI

"op

400

A£ 300

eg

ge" 20o

uo=-

ge 100

o

e

o

Pi=8Ol(Pa

P2=180vea

t,=O. 8s

N=4000rpm

e

o

e

o-O' an-e- 6

e

o

3%Zr 7%Zn 20%Zn 3%siChanges in tensile strength and total burn-off quantity with various aluminum alloys.

15

A E e v to

10 b

.d

g

gs

5£g

g

o

40

AG 3o:2g ,,;coi

::.I

gY 10

e/

o/

ox

-O- aB-e- 6

Pi=50}[Pa

P2=240ur'a

tt=O. 8s

15

arg

10 .h ･-ri

gv

s

5£ s 8

o 2000 OO 4000 Rotation speed N (rpm) Fig. 10 Changes in tensile strength and total burn-off quantit,y with rotation speed.

an insert metal increased in spite of the thick remain-

ing insert metal because the tensile strength of Al-3%

Mg alloy (147MPa) was higher than that of AI050

(98MPa). The tensile fractured surface (S45C side) of

this welded joint is shown in Fig. 15. The surface of

the S45C side is almost covered with the insert metal,

but S45C itself is partially observed. This means that

tensile fracture occurs both in the insert metal and at

the interface between insert metal and S45C.

Friction welding

carbon steel was

4. Conclusions

of 2017 aluminum alloy

carried out using insert

40

g. 3oU･

g ,,e･

gS 100

o

-o-o-o>7(Ceo××

e/e ox

/ e

-Om os-e-6

Pi=50MPa

P2=240UPa

N=3000rptu

15

10

5

and S45C

metals of

Agvig

ts,,-.I.

gcr

:9E8'IEIP.ts

o ･.. . 1. Friction time ti (s) Fig. 11 Changes in tensile strength and total

burn-off quantity with friction time.

AI050 aluminum and various aluminum alloys. When

the remaining insert metal was thick, absent or mixed

with A2017 at the welded interface, the joint strength

decreased. On the other hand, when thin and homo-qeneous insert metal remained, the joint strength in-

creased. It was clarified that the insert metal played

the role of a partition between two metals to be

welded. And it seems that thejoint strength depended

on the Strength of the insert metal used. Successful

welds were produced by using insert metals of both

AI050 and aluminum alloy composed of Al-3% Mg,

and the strength were 280MPa and 380MPa, respective-

ly.

Fbiction VV'lalding of Ainminum Allay and th7bon Steel Clsing insert Mblal 117

40

E 3oU･

g 2o

,..J

eH.-va

S 10

o/

o/

o/ /e/

-o/ /e o

/e Pi=501(Pa

-O- aB ti=O.5s -e- 6 N=3oeoxpm

120 180 24e 30 Forging pressure P2 (MPa)

Changes in tensile strength and

burn-off quantity with forging

sure.

15

A g N.Y

lo

10 x ･"H

a g cr u ? s

5£ g ts

o

total

pres-

Fig. 14 Appearance of interfacia! layer of welded joint.

Fig. 12

40

Ag 3o

g

g ,,

tsopo:cogB 10

-- e

o/

oN.

.,,e/8

-o--e-

as6

e/

x,,,

ox

P2=300

ti=O. 5s

N=3000rpm

35 5 65 80 Friction pressure PL (MPa)

Changes in tensile strength and

burn-off quantity with friction

sure.

15

A g v fo

lo t. ･-ri

"a g cr u ? s

5£ g e

Fig. 13

o

total

pres-

Fig. 15 Appearance ofsurface (S45Cjoint.

tensile fractured

side) of welded

tion, 22, 310 (1984).

2) F. Sassani and J. R. Neelam: Welding Reseach Supple-

ment, 264-s, (1988).

3) K. Ogawa, H. Ochi, Y. Yamamoto, M. Habe, T. Iwamoto and Y. Suga: Journal of Light Metal Welding & Construc-

tion, 32, 3 (1994).

4) H. Ochi, K. Ogawa, Y. Yamamoto, M. Habe and Y. Suga: Journal of Japan Institute of Light Metals, 44, 320 (1994),

Referenees

1)

S. Imaizumi: J ournal of Light Metal Welding & Construc-