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<p>DH36 steel, a shipbuilding structural steel, and aluminum alloy 6061 (AA6061), a high-strength heat-treatable aluminum alloy with excellent corrosion resistance and weldability, were joined using dissimilar friction stir welding (FSW). The study explores the effects of welding speeds (40, 90, and 140&#xa0;mm/min) at a constant tool rotational speed of 875&#xa0;rpm on weld quality and material behavior. The optimal tensile strength of 185.65&#xa0;MPa (68.11% of AA6061 base strength) was achieved at 90&#xa0;mm/min. Metallographic analysis revealed sound weld formation with continuous steel strip embedding in the aluminum matrix, facilitating mechanical interlocking. The maximum temperature at the tool shoulder-workpiece interface was 899&#xa0;K on the advancing side (AS) and 824&#xa0;K on the retreating side (RS), confirming the necessity of higher AS temperatures to ensure effective material flow and minimize groove defects. A multi-species transport-based CFD model simulated thermal history, strain rate, and material flow with high fidelity to experimental results. The peak strain rate of 1650&#xa0;s<sup>-1</sup> occurred near the tool shoulder due to high amount of plastic deformation. XRD confirmed FeAl and Fe<sub>3</sub>Al intermetallics in the mixed zone (MZ). This integrated approach enhances understanding of thermomechanical interactions in dissimilar FSW, providing valuable insights for high-integrity steel-aluminum joint design.</p>

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Metallographic Characterization and Multi-species Transport Simulation of Dissimilar High-Strength DH36 Shipbuilding Steel and AA6061 via Friction Stir Welding

  • 期刊论文

  • 发表日期：

    2025年9月26日

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  • Rituraj Bhattacharjee,
  • Pardeep Pankaj,
  • Ankan Pramanik,
  • Pankaj Biswas

摘要

DH36 steel, a shipbuilding structural steel, and aluminum alloy 6061 (AA6061), a high-strength heat-treatable aluminum alloy with excellent corrosion resistance and weldability, were joined using dissimilar friction stir welding (FSW). The study explores the effects of welding speeds (40, 90, and 140 mm/min) at a constant tool rotational speed of 875 rpm on weld quality and material behavior. The optimal tensile strength of 185.65 MPa (68.11% of AA6061 base strength) was achieved at 90 mm/min. Metallographic analysis revealed sound weld formation with continuous steel strip embedding in the aluminum matrix, facilitating mechanical interlocking. The maximum temperature at the tool shoulder-workpiece interface was 899 K on the advancing side (AS) and 824 K on the retreating side (RS), confirming the necessity of higher AS temperatures to ensure effective material flow and minimize groove defects. A multi-species transport-based CFD model simulated thermal history, strain rate, and material flow with high fidelity to experimental results. The peak strain rate of 1650 s-1 occurred near the tool shoulder due to high amount of plastic deformation. XRD confirmed FeAl and Fe3Al intermetallics in the mixed zone (MZ). This integrated approach enhances understanding of thermomechanical interactions in dissimilar FSW, providing valuable insights for high-integrity steel-aluminum joint design.