Feasibility study on dissimilar joint between Alclad AA2024-T3 and DC04 steel by friction stir welding

This study delves into the intricacies of the friction stir welding (FSW) process when applied to the joining of Alclad AA2024-T3 and DC04 steel. The effects of process parameters on the quality and property of welded sample evaluated. The methodology entails subjecting aluminum and steel to the FSW procedure while systematically varying traverse speeds. The resultant joints are meticulously characterized through comprehensive force analysis, joint quality assessment, microhardness measurements, and tensile strength evaluations. The correlation between increased traverse speed and heightened average axial forces acting upon the tool underscores the direct interplay between speed and the mechanical forces involved. Conversely, a deliberate reduction in traverse speed facilitates the creation of superior material mixing and the formation of intricate wavy interlocks at the interface of the base metals, thereby accentuating the crucial influence of process parameters on joint microstructure. Furthermore, the study unveils the pivotal protective role played by the Alclad coating in thwarting the development of bulky intermetallic compounds that can imperil joint integrity. The culmination of these findings is the identification of the optimal joint configuration, realized at 1500 rpm and a traverse speed of 50 mm/min. This specific configuration outshines the others, achieving an impressive tensile strength surpassing the steel base metal by more than 100.5%.