High-frequency linear friction welding of aluminum alloys to stainless steel

Joining of 5083 and 6063 aluminum alloys to 304 stainless steel was successfully achieved by high-frequency linear friction welding working at 245 Hz with varied friction pressure and time, which affect the heat input. Increasing the friction pressure and friction time resulted in the softening of aluminum alloys, which facilitated plastic flow and subsequent squeezing behavior. The morphology of the intermetallic compound layer, dependent on the plastic flow, determined the performance of 5083 aluminum alloy/steel joints. Excessive friction pressure and time led to inefficient welding in 6063 aluminum alloy/steel joints because the softening and squeezing behavior of the heat-treatable alloy was susceptible to the heat input. Highly efficient joints were obtained in a short duration, i.e., 1 s, through the formation of a thin intermetallic compound layer at the interface below 500 and 50 nm for 5083 and 6063 aluminum alloy/steel joints by controlling the appropriate friction pressure. High-frequency linear friction welding was demonstrated to be effective for the sound joining of various materials by controlling the friction pressure.