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<p>The friction welding of a tube to a tube plate using an external tool (FWTPET) process was investigated for joining dissimilar materials AA6061 aluminum alloy and ASTM A106 grade B alloy steel. The influence of varying tool rotational speeds, viz. 1200, 1400, and 1600&#xa0;rpm, on the microstructural development and mechanical properties of the welded joints was examined. Microstructural characterization revealed dynamic recrystallization on the AA6061 side, resulting in fine equiaxed grains with an average size of 17.7&#xa0;μm, while the A106 alloy steel side exhibited recrystallized finer grains with an average size of 16.27&#xa0;μm. The formation of FeAl<sub>3</sub> intermetallic compounds at the joint interface was confirmed by XRD analysis. SEM-EDS line scan analysis demonstrated the diffusion of aluminum and iron atoms across the interface. The IMC layer thickness consists of FeAl<sub>3</sub> and Fe<sub>2</sub>Al<sub>5</sub> increased monotonically with tool rotational speed, ranging from 5.6 to 16.5&#xa0;μm. Microhardness profiles indicated a sharp increase in hardness at the interface due to the presence of brittle intermetallics. Pull tests revealed that the specimen processed at 1400&#xa0;rpm exhibited the highest strength of 85.3&#xa0;MPa compared to those processed at 1200 and 1600&#xa0;rpm. Fractography analysis indicated a brittle failure mode for all specimens, characterized by the absence of a dimpled structure with cleavage facets. Findings emphasize that the process parameters play a vital role to control the FeAl<sub>3</sub> and Fe<sub>2</sub>Al<sub>5</sub> IMC thickness, ensuring robust and reliable joints in FWTPET applications for AA6061 aluminum and A106 steel.</p> Graphical Abstract <p></p>

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Microstructural and Mechanical Implications of Tool Speed Variations in Dissimilar Friction Welding of Steel Tubes and Aluminum Plates Using FWTPET

  • 期刊论文

  • 发表日期：

    2025年6月9日

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  • K. T. Sabu,
  • Amal V. Purushothaman,
  • S. Muthukumaran,
  • Sunilkumar Dhasan

摘要

The friction welding of a tube to a tube plate using an external tool (FWTPET) process was investigated for joining dissimilar materials AA6061 aluminum alloy and ASTM A106 grade B alloy steel. The influence of varying tool rotational speeds, viz. 1200, 1400, and 1600 rpm, on the microstructural development and mechanical properties of the welded joints was examined. Microstructural characterization revealed dynamic recrystallization on the AA6061 side, resulting in fine equiaxed grains with an average size of 17.7 μm, while the A106 alloy steel side exhibited recrystallized finer grains with an average size of 16.27 μm. The formation of FeAl3 intermetallic compounds at the joint interface was confirmed by XRD analysis. SEM-EDS line scan analysis demonstrated the diffusion of aluminum and iron atoms across the interface. The IMC layer thickness consists of FeAl3 and Fe2Al5 increased monotonically with tool rotational speed, ranging from 5.6 to 16.5 μm. Microhardness profiles indicated a sharp increase in hardness at the interface due to the presence of brittle intermetallics. Pull tests revealed that the specimen processed at 1400 rpm exhibited the highest strength of 85.3 MPa compared to those processed at 1200 and 1600 rpm. Fractography analysis indicated a brittle failure mode for all specimens, characterized by the absence of a dimpled structure with cleavage facets. Findings emphasize that the process parameters play a vital role to control the FeAl3 and Fe2Al5 IMC thickness, ensuring robust and reliable joints in FWTPET applications for AA6061 aluminum and A106 steel.

Graphical Abstract