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Friction Stir Welding and Processing X pp 23–32Cite as

Ultrasound Enhanced Friction Stir Welding (USE-FSW) of Hybrid Aluminum/Steel Joints

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Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

Ultrasound Enhanced Friction Stir Welding (USE-FSW ) is an innovative hybrid method for solid-state joining. This process resulted in remarkably positive findings in the successful realization of hybrid aluminum/magnesium joints as well as in first investigations on the microstructure of aluminum/steel joints due to the parallel and synchronous transmission of power ultrasound into one of the joining partners. The present work investigates the impact of additional power ultrasound on the mechanical properties of AA6061 /SAE1006-joints by comparing FSW and USE-FSW . Therefore, light microscopy, as well as scanning electron microscopy, was carried out for examining the microstructure of the joints. Furthermore, mechanical tests on the microhardness of the weld zone of the joints as well as tensile and first fatigue tests were examined. The investigations proved an influence of the power ultrasound by a change in the morphology of the nugget. It showed to be more cleared up and also contains a thinner intermetallic phase of FeAl3 at the interface aluminum to steel. Furthermore, an increase in the tensile strength of the joints of about 15% could be observed. First stepwise load increase tests resulted in slightly different stress levels for the estimated fatigue limit.

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Acknowledgements

We would like to thank the German Research Foundation (DFG) for the support of the present work as a part of the Priority Program 1640 “Joining by Plastic Deformation”.

Author information

Authors and Affiliations

  1. Institute of Materials Science and Engineering, Chemnitz University of Technology, 09107, Chemnitz, Germany

    Marco Thomä & Guntram Wagner

  2. Fraunhofer Institute for Nondestructive Testing IZFP, Campus E3 1, 66123, Saarbrücken, Germany

    Benjamin Straß & Bernd Wolter

  3. DECHEMA-Forschungsinstitut, Theodor-Heuss-Allee 25, 60486, Frankfurt am Main, Germany

    Sigrid Benfer & Wolfram Fürbeth

Authors
  1. Marco Thomä
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  2. Guntram Wagner
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  3. Benjamin Straß
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  4. Bernd Wolter
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  5. Sigrid Benfer
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  6. Wolfram Fürbeth
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Corresponding author

Correspondence to Marco Thomä .

Editor information

Editors and Affiliations

  1. Brigham Young University, Provo, UT, USA

    Yuri Hovanski

  2. University of North Texas, Denton, TX, USA

    Rajiv Mishra

  3. Tohoku University, Sendai, Japan

    Yutaka Sato

  4. Pacific Northwest National Laboratory, Richland, WA, USA

    Piyush Upadhyay

  5. San Jose State University, San Jose, CA, USA

    David Yan

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© 2019 The Minerals, Metals & Materials Society

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Cite this paper

Thomä, M., Wagner, G., Straß, B., Wolter, B., Benfer, S., Fürbeth, W. (2019). Ultrasound Enhanced Friction Stir Welding (USE-FSW) of Hybrid Aluminum/Steel Joints. In: Hovanski, Y., Mishra, R., Sato, Y., Upadhyay, P., Yan, D. (eds) Friction Stir Welding and Processing X. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-05752-7_3

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