Friction Stir Welding 07 Joining of Al 6061 alloy to AISI 1018 steel by combined effects of fusion and solid state welding英文电子书.pdf

International Journal of Machine Tools Manufacture 44 (2004) 1205–1214 /locate/ijmactool Joining of Al 6061 alloy to AISI 1018 steel by combined effects of fusion and solid state welding C.M. Chen, R. Kovacevic Department of Mechanical Engineering, Research Center for Advanced Manufacturing, Southern Methodist University, 1500 International Parkway, Suite 100, Richardson, TX 75081, USA Received 28 November 2003; received in revised form 17 March 2004; accepted 23 March 2004 Abstract The joining of a 6-mm thickness Al 6061 to AISI 1018 steel has been performed by the combined effects of fusion and solid state welding. The process is derived from friction stir welding (FSW) but with an adjustable offset of the probe location with respect to the butt line. Metallographic studies by optical microscopy, electron probe microscopy, and the utilization of the X-ray diffraction technique have been conducted. It was found that the intermetallic phases Al Fe and Al Fe exist in the weld zone. 13 4 5 2 The tool was significantly worn during welding and is broken after traveling 100 mm at a rotational speed of 917 rpm. The wear of the tool significantly affects the structure of the weld, and the tool breakage was detected by the incorporated acoustic emission (AE) sensors. It appears that the joining of an Al 6061 alloy to AISI 1018 steel with a sound heterogeneous weld microstructure is feasible using this process, and the tool breakage can be detected by the AE sensing techni