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<p>Friction stir welding (FSW) is a suitable method for joining dissimilar materials. However, with respect to Al/steel joints with unequal thicknesses, conventional butt joining results in a limited effective bonding area, whereas conventional lap joining causes severe pin wear, a high risk of tool fracture, and increased bending moment and space occupation. In this study, a new combined butt−lap joint design for joining a 6&#xa0;mm 6061-T6 Al alloy to 3&#xa0;mm 304 stainless steel was proposed. Four different types of combined butt–lap joints for unequal-thickness Al/steel were developed and compared with the two conventional joints. The results indicated significant variations in the microstructures and mechanical properties with different joint types because the combined joints enabled effective bonding at both the butt and lap interfaces. In particular, the Type-C joint was characterized by reinforced mechanical interlocking between Al and steel, a thin single layer of IMCs at the lap interface, and continuous intercalated structures at the butt interface. As a result, the fracture load of the Type-C combined butt–lap joint was 892.03 N/mm, which was 43 and 79 pct greater than those of the conventional butt joints and conventional lap joints, respectively.</p>

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A Combined Butt−Lap Joint Design for Friction Stir Welding of Dissimilar Al/Steel with Unequal Thickness

  • 期刊论文

  • 发表日期：

    2026年5月17日

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  • Feng Zhang,
  • Hao Su,
  • Ji Chen,
  • ChuanSong Wu

摘要

Friction stir welding (FSW) is a suitable method for joining dissimilar materials. However, with respect to Al/steel joints with unequal thicknesses, conventional butt joining results in a limited effective bonding area, whereas conventional lap joining causes severe pin wear, a high risk of tool fracture, and increased bending moment and space occupation. In this study, a new combined butt−lap joint design for joining a 6 mm 6061-T6 Al alloy to 3 mm 304 stainless steel was proposed. Four different types of combined butt–lap joints for unequal-thickness Al/steel were developed and compared with the two conventional joints. The results indicated significant variations in the microstructures and mechanical properties with different joint types because the combined joints enabled effective bonding at both the butt and lap interfaces. In particular, the Type-C joint was characterized by reinforced mechanical interlocking between Al and steel, a thin single layer of IMCs at the lap interface, and continuous intercalated structures at the butt interface. As a result, the fracture load of the Type-C combined butt–lap joint was 892.03 N/mm, which was 43 and 79 pct greater than those of the conventional butt joints and conventional lap joints, respectively.