Microstructure and Fatigue Behaviors of Dissimilar A6061/Galvannealed Steel Joints Fabricated by Friction Stir Spot Welding
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
3.1. Microstructures of Joints
3.2. Tensile Shear Properties
3.3. Tensile Shear Fatigue Properties
4. Conclusions
- (1)
- Fe4Al13 phases form as the IMC layer at the joint interface between the A6061 matrix and the galvannealed layer of GA980 consisting of FeZn7, Fe and Zn. At the edge of the joint, the stirred layer, which consists of the A6061 matrix and the galvannealed layer, forms between the A6061 matrix and the IMC layer. Moreover, the solidification of the residual melt discharged from the joint area occurs at the outer peripheries of the joint.
- (2)
- An analogous tensile shear force was obtained regardless of the welding time, although the thickness of the remainder of the A6061 sheet in the welded area decreased with an increase in the welding time. In the tensile shear test, the crack generated in the solidified part of the residual melt or at the interface between the solidified part of the residual melt and Fe4Al13 and mainly progressed at the interface between the stirred layer and Fe4Al13.
- (3)
- Analogous fatigue properties were obtained regardless of the welding time. At the high cycle fatigue region in which the number of cycles to failure is more than around 105 cycles, fatigue fracture occurred in the A6061 matrix. In contrast, at the low cycle fatigue region in which the number of cycles to failure is less than 105 cycles, interfacial fracture occurred. In the case of the interfacial fracture, the crack is generated in the solidified part of the residual melt or at the interface between the solidified part and the stirred layer and progresses in the stirred layer and the interface between the stirred layer and the IMC layer.
- (4)
- For the fatigue strength of 105 cycles, the dissimilar FSSW joints investigated in this study are superior or equal to those of the dissimilar FSSW joints with Al alloy and steel investigated in previous studies.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Analysis Point | Al | Fe | Mg | Si | Zn (at%) | Inferred Phase |
---|---|---|---|---|---|---|
➀ | 75.0 | 22.6 | 0.3 | 0.4 | 1.7 | Fe4Al13 |
➁ | 77.1 | 20.3 | 0.7 | 0.2 | 1.7 | Fe4Al13 |
➂ | 76.2 | 21.5 | 0.1 | 0.5 | 1.8 | Fe4Al13 |
➃ | 79.4 | 16.8 | 0.2 | 0.6 | 3.1 | Fe4Al13 |
➄ | 76.4 | 17.8 | 1.1 | 0.8 | 3.9 | Fe4Al13 |
➅ | 87.2 | 0.9 | 0.5 | 0.2 | 11.2 | A6061 and GA plating |
Welding Time (s) | Specimen No. | Tensile Shear Force (kN) | Fracture Mode |
---|---|---|---|
9 | No. 1 | 5.73 | Plug destruction |
No. 2 | 5.52 | A6061/GA980 interfacial fracture | |
10 | No. 1 | 5.56 | A6061/GA980 interfacial fracture |
No. 2 | 5.47 | Plug destruction |
Al Alloy | Steel | Fatigue Test Parameter | Fatigue Strength at 105 Cycles | Reference | ||||
---|---|---|---|---|---|---|---|---|
Type | Thickness (mm) | Type | Thickness (mm) | Frequency (Hz) | Stress Ratio | Wave | ||
A6061 | 1.6 | GA980 | 1.4 | 10 | 0.1 | sine | ≈3 kN | this study |
A5052 | 1.0 | SPC270C | 1.0 | 20 | 0.05 | sine | ≈1 kN | [30] |
A5052 | 2.0 | 980DP-GA | 1.4 | 10 | 0.05 | sine | ≈2 kN | [3] |
A6061 | 2.0 | SPCC | 2.0 | 10 | 0.1 | sine | 2–2.5 kN | [29] |
A6082 | 2.0 | DP600 | 1.0 | 20 | 0.1 | sine | ≈3 kN | [37] |
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Kumamoto, K.; Kosaka, T.; Kobayashi, T.; Shohji, I.; Kamakoshi, Y. Microstructure and Fatigue Behaviors of Dissimilar A6061/Galvannealed Steel Joints Fabricated by Friction Stir Spot Welding. Materials 2021, 14, 3877. https://doi.org/10.3390/ma14143877
Kumamoto K, Kosaka T, Kobayashi T, Shohji I, Kamakoshi Y. Microstructure and Fatigue Behaviors of Dissimilar A6061/Galvannealed Steel Joints Fabricated by Friction Stir Spot Welding. Materials. 2021; 14(14):3877. https://doi.org/10.3390/ma14143877
Chicago/Turabian StyleKumamoto, Koki, Tsuyoshi Kosaka, Tatsuya Kobayashi, Ikuo Shohji, and Yuichiro Kamakoshi. 2021. "Microstructure and Fatigue Behaviors of Dissimilar A6061/Galvannealed Steel Joints Fabricated by Friction Stir Spot Welding" Materials 14, no. 14: 3877. https://doi.org/10.3390/ma14143877