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Open AccessArticle

Effect of Revolutionary Pitch on Interface Microstructure and Mechanical Behavior of Friction Stir Lap Welds of AA6082-T6 to Galvanized DP800

1
CanmetMATERIALS, Natural Resources Canada, 183 Longwood Road South, Hamilton, ON L8P 0A5, Canada
2
School of Aerospace Manufacturing Engineering, Nanchang Hangkong University, 696 Fenghe Road South, Nanchang 330063, China
3
National Research Council of Canada (NRC), Saguenay, QC G7H 8C3, Canada
*
Authors to whom correspondence should be addressed.
Metals 2018, 8(11), 925; https://doi.org/10.3390/met8110925
Received: 24 October 2018 / Revised: 5 November 2018 / Accepted: 5 November 2018 / Published: 9 November 2018
(This article belongs to the Special Issue Dissimilar Metal Welding)
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Abstract

Friction stir lap welding of 1.5-mm thick 6082-T6 aluminum alloy to 2-mm thick galvanized DP800 steel (Zn-coated) was carried out. Optimal welding conditions were obtained aiming to defect-free joints with good mechanical properties. The interfacial intermetallic compounds (IMCs) at the stir zone and hook zone were characterized under different revolutionary pitches. With a revolutionary pitch of 1.0 mm/rev, maximum joint strength reached 71% of that of the aluminum alloy. In the meantime, the average thickness of IMC layer is less than 1 μm; Al3.2Fe in the Al-rich side and Al5Fe2 in the Fe-rich side at the interfaces of stir zone while Al6Fe and nanocrystalline close to Al3.2Fe at the interface of the hook zone. At a relatively lower revolutionary pitch (0.5 mm/rev), Zn was found with the aggregation of Si and Mn at the hook-zone interface, leading to the generation of Al-Fe-Si phase thus decreasing the thickness of the IMC layer. In the stir zone, the revolutionary pitch has a significant influence on the interfacial microstructures. The interfacial IMC layer at 1.0 mm/rev is simple and flat, but the one at 0.5 mm/rev becomes thicker and more complex. Stir zone aluminum under different revolutionary pitches is similar in microhardness and tensile behavior. The mechanical response of joints was modeled based on linear mixture law with an iso-strain assumption and neglection of the IMC layer. The modeling results are in good agreement with the experimental ones indicating the resultant interfaces act as good as the good boundaries between dissimilar Al/steel joints. View Full-Text
Keywords: Al/steel dissimilar materials; friction stir welding; interface; intermetallic compounds Al/steel dissimilar materials; friction stir welding; interface; intermetallic compounds
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Li, S.; Chen, Y.; Kang, J.; Shalchi Amirkhiz, B.; Nadeau, F. Effect of Revolutionary Pitch on Interface Microstructure and Mechanical Behavior of Friction Stir Lap Welds of AA6082-T6 to Galvanized DP800. Metals 2018, 8, 925.

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