Search

The development of new joint configurations suitable for dissimilar materials enables a wider range of applications and allows for an accelerated replacement of traditional structural construction materials by lightweight materials. The T-configuration is a joint configuration that has not been sufficiently studied for use with dissimilar materials, especially when created using the friction stir welding (FSW) process. In this study, a combined lap/butt design was introduced and implemented, seeking to create a T-joint between aluminum and steel. Characterization of the joints showed that FSW could be successfully used to join aluminum and steel in a T-configuration. The formation of intermetallic bonds and kissing bonds was carefully analyzed, and their contribution to the fracture behavior during loading in the skin and stringer directions was studied. Finite element simulation was used to determine the stress state at the interface during loading. The characterization results showed that the intermetallic, as an indicator of metallurgical bonding, is formed when special features are observed in the pattern of material flow. The fractography images showed that the stress state has a major impact on the fracture. The results of the present study can be effectively used to design and fabricate dissimilar joints, taking into account the loading condition.

Friction stir welding (FSW) is a process by which a joint can be made in a solid state. The complexity of the process due to metallurgical phenomena necessitates the use of models with the ability to accurately correlate the process parameters with the joint properties. In the present study, a multilayer perceptron (MLP) artificial neural network (ANN) was used to model and predict the ultimate tensile strength (UTS) of the joint between the AA2024 and AA7075 aluminum alloys. Three pin geometries, pyramidal, conical, and cylindrical, were used for welding. The rotation speed varied between 800 and 1200 rpm and the welding speed varied between 10 and 50 mm/min. The obtained ANN model was used in a simulated annealing algorithm (SA algorithm) to optimize the process to attain the maximum UTS. The SA algorithm yielded the cylindrical pin and rotational speed of 1110 rpm to achieve the maximum UTS (395 MPa), which agreed well with the experiment. Tensile testing and scanning electron microscopy (SEM) were used to assess the joint strength and the microstructure of the joints, respectively. Various defects were detected in the joints, such as a root kissing bond and unconsolidated banding structures, whose formations were dependent on the tool geometry and the rotation speed.