Resistance Spot Welding of Dissimilar Alloys 1008 Low Carbon Steel- 1100 Aluminum Alloy

The resistance spot welding is adopted to joint dissimilar alloys such as aluminum alloy 1100 , and low carbon steel alloy 1008 by using cover plate. This study aims to optimization the best conditions of dissimilar welding of Aluminum with low carbon steel by RSW, and improving the properties of joints by many method. three different variables were used for the welding process: welding current (5, 6 ,7 and 8 KA), weld time (0.5, 1 and 1.5 sec) and electrode force (13.2 and 15.5 N).The welding joints are ―examined by a scanning electron microscope SEM and a X-ray diffraction‖ for the purpose of discussing the causes of the improved characteristics. The results revealed that the best welding conditions were under welding current 7 KA , weld time 1 sec and electrode force 13.2 KN, where the joint possessed the maximum shear force (4.8KN) and after improvement the tensile shear force become (6.02 KN), in addition to presence of the intermetallic compounds at optimum condition , such as AlFe3,Al5Fe4 and Al13Fe4, in the joint layer between dissimilar metal improves of the tensile shear forces and hardness in fusion zone.

The Effect of Tool Rotation Speed on Hardness, Tensile Strength, and Microstructure of Dissimilar Friction Stir Welding of Dissimilar AA5083 and AA6061-T6 Alloys

The welding between two different grades of aluminum alloy, specifically AA5083 and AA6061-T6, is very difficult to obtain optimal results when using conventional welding methods such as TIG/MIG welding. Therefore, a solid-state joining technique is highly recommended to overcome these problems, one of which is friction stir welding (FSW). The effect of rotation speed on microstructure, microhardness, and tensile properties of dissimilar Friction Stir welded AA5083 and AA6061-T6 aluminum alloys were investigated. Three different rotation speeds (910, 1500, and 2280 rpm) were used to weld the dissimilar alloys. The metallographic analysis of joints showed the presence of various zones such as BM (base material), HAZ (heat affected zone), TMAZ (thermo-mechanically affected zone), and NZ (nugget zone) were observed and analyzed by mean of optical and scanning electron microscope. The results showed that increasing the rotation speed from 900 to 2280 rpm made grain coarsening in NZ and the mass distribution of the material is more evenly distributed, as well as increased hardness and tensile strength of the joint. The highest values in microhardness in NZ and tensile strength at the join were founded at the speed of 2280 rpm and 1500 rpm which was similar to 2280 rpm, respectively.

Enhancement of the Al/Mg Dissimilar Friction Stir Welding Joint Strength with the Assistance of Ultrasonic Vibration

The assistance of ultrasonic vibration during the friction stir welding (FSW) process has been verified as an effective approach for the improvement of joint strength. In the present study, experimentation on Al/Mg dissimilar alloys in butt joint configuration is implemented by employing FSW with and without the assistance of ultrasonic vibration. An optimized tool shoulder diameter of 12 mm is utilized, and the ultrasonic vibration is applied perpendicularly onto the tool along the welding direction, which is named UVaFSW. The results of joint appearance and macrostructure, characteristics of the intermetallic compounds (IMCs), as well as joint strength and fracture appearance are compared between Al/Mg FSW joints with and without ultrasonic vibration. It is demonstrated that the material intermixing between Al and Mg alloys is substantially strengthened in the UVaFSW joint compared with that in the FSW joint. Additionally, the ultrasonic vibration can be beneficial for the reduction of IMC thickness, as well as the formation of intermittently distributed IMC phases at the Al–Mg bonding interface. Consequently, the mechanical properties of Al/Mg FSW joints are significantly improved with the assistance of ultrasonic vibration. The maximum ultimate tensile strength is 206 MPa at tool rotation speed of 800 rpm and welding speed of 50 mm/min for the Al/Mg UVaFSW joint.

Development of arc welding technique to preclude microsegregation in the dissimilar joint of Alloy C-2000 and C-276

Hastelloy C-2000 and C-276 are widely used in Flue Gas Desulphurization (FGD) system and Chemical Processing Industries (CPI). Current work is focused on weld microstructure, and mechanical properties (structure-property relationship) of the dissimilar combination of alloy C-2000 and C-276. Multi-pass Pulsed Current Gas Tungsten Arc (PCGTA) welding was adopted for joining the dissimilar alloys using the filler ERNiCrMo-17. Microstructural characteristics of the weld joint were assessed by Optical and Scanning Electron Microscope (SEM). Weld interface microstructure examination revealed the presence of grain coarsening near the Heat Affecting Zone (HAZ) of the alloy C-276 side. SEM analysis shows the absence of secondary Topologically Closed Packed (TCP) phases in the Inter-Dendritic (ID) regions of the dissimilar weld. Micro-segregation of alloying elements in the weldment was assessed by Energy-Dispersive X-ray Spectroscopy (EDS). X-Ray Diffraction (XRD) analysis had been carried out to identify the phase constitution and average grain size. Strength, toughness, and hardness of the dissimilar weld were evaluated with the support of the tensile test, Charpy impact test, and Vicker’s hardness test. Tensile study showed that all the tensile fracture occurred at the base metal side of alloy C-276. The average toughness of the dissimilar alloy joint was noted about 84 J. Hardness test results indicated that fusion zone (FZ) hardness value was 6.19% and 2.27% superior to the candidates’ material (C-276 and C-2000) employed in this study. The refined grain structure and absence of microsegregation resulted in the highest hardness in the dissimilar weld FZ. Results revealed the substantiated use of PCGTA welding for the effective joining of dissimilar alloys of C-2000 and C-276 through the evaluation of metallurgical and mechanical characteristics.