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<p>This study examines the dissimilar joining of AA 6061-T6 aluminum and HSLA 340 steel alloys using the friction stir-assisted scribe technique (FaST) on a cost-effective conventional vertical milling machine. Two distinct single-material tools, AISI H13 tool steel and WC-12%Co, were employed to assess the impact of tool material and geometry on joint formation, intermetallic compound (IMC) development, and mechanical performance. In contrast to previous studies that employed bi-material tooling and specialized CNC-position and force-controlled setups, this study explored the feasibility of implementing FaST in resource-constrained manufacturing environments. Three welding trials were conducted using various process parameters. The joint fabricated with the WC-12%Co tool at a tool rotational speed of 900&#xa0;rpm, weld speed of 20&#xa0;mm/min, and tool tilt angle of 0.5° exhibited superior tensile strength (~260&#xa0;MPa), which was approximately 84% of the base strength of the aluminum alloy. Microstructural analysis using XRD and SEM–EDS confirmed the presence of Fe<sub>2</sub>Al<sub>5</sub> and Fe<sub>2</sub>Al<sub>9</sub> IMCs with a maximum thickness of ~ 1.8&#xa0;µm, uniformly distributed across the weld interface. The hook geometry analysis indicated a minimized hook height and improved mechanical interlocking under the optimized conditions. Furthermore, the use of WC tooling mitigated the tool wear issues observed in the H13 tool steel trials, thereby enhancing the weld consistency. Hardness measurements revealed higher values on the advancing side owing to severe plastic deformation. This study demonstrates that FaST, when optimized with simplified tooling and appropriate parameters, facilitates robust Al–steel joints without the need for advanced equipment, underscoring its potential for industrial-scale applications in lightweight hybrid structures.</p>

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Study of Steel–Aluminum Alloy Joint Using Friction Stir-Assisted Scribe Technique

  • 期刊论文

  • 发表日期：

    2025年8月14日

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  • N. S. Khemnar,
  • V. S. Gadakh,
  • M. Sahu,
  • V. J. Badheka

摘要

This study examines the dissimilar joining of AA 6061-T6 aluminum and HSLA 340 steel alloys using the friction stir-assisted scribe technique (FaST) on a cost-effective conventional vertical milling machine. Two distinct single-material tools, AISI H13 tool steel and WC-12%Co, were employed to assess the impact of tool material and geometry on joint formation, intermetallic compound (IMC) development, and mechanical performance. In contrast to previous studies that employed bi-material tooling and specialized CNC-position and force-controlled setups, this study explored the feasibility of implementing FaST in resource-constrained manufacturing environments. Three welding trials were conducted using various process parameters. The joint fabricated with the WC-12%Co tool at a tool rotational speed of 900 rpm, weld speed of 20 mm/min, and tool tilt angle of 0.5° exhibited superior tensile strength (~260 MPa), which was approximately 84% of the base strength of the aluminum alloy. Microstructural analysis using XRD and SEM–EDS confirmed the presence of Fe2Al5 and Fe2Al9 IMCs with a maximum thickness of ~ 1.8 µm, uniformly distributed across the weld interface. The hook geometry analysis indicated a minimized hook height and improved mechanical interlocking under the optimized conditions. Furthermore, the use of WC tooling mitigated the tool wear issues observed in the H13 tool steel trials, thereby enhancing the weld consistency. Hardness measurements revealed higher values on the advancing side owing to severe plastic deformation. This study demonstrates that FaST, when optimized with simplified tooling and appropriate parameters, facilitates robust Al–steel joints without the need for advanced equipment, underscoring its potential for industrial-scale applications in lightweight hybrid structures.