Study of Microstructure and Properties of Aluminum/Steel Inertia Radial Friction Welding

In this paper, 6061-T6 aluminum alloy and 30CrMnSiA steel are bonded by inertia radial friction welding (IRFW). The formation mechanism of the aluminum/steel friction welded joints and the effect of the welding parameters on the mechanical properties are investigated through the microstructure, microzone composition, and mechanical property analysis. The results show that no visible intermetallic compound layers (IMCs) are detected on the aluminum/steel welding interface, which may be due to Si element aggregating in the welding interface and then forming a Al−Fe−Si phase, preventing the formation and growth of an Al−Fe IMCs. Eventually, a micron ultrathin interface reaction layer composed of Al0.7Fe3Si0.3, FeAl, and Fe3Al phases is formed at the aluminum/steel welding interface. The maximum average shear strength of the joint is 176 MPa. The shear fracture is a typical ductile fracture. Properly reducing the friction speed and increasing the upsetting pressure can improve the bonding strength of aluminum/steel joints.