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<p>This study investigates the friction stir welding (FSW) process for joining a novel combination of dissimilar materials, specifically aluminum alloy Al5052 and high-temperature–resistant P22 steel plates. This research evaluates the joint formation mechanism and the extent of metallurgical mixing in dissimilar Al-steel joints by characterizing the intermetallic layer formed at the interface. Metallographic characterization techniques such as optical microscopy, scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS), and electron backscatter diffraction (EBSD) were used for comprehensive analysis of the joint interface. This investigation demonstrated the successful formation of defect-free joints with a well-mixed interface and a thin, uniform intermetallic compound (IMC) layer, measuring 1–8&#xa0;µm. Tensile testing revealed an ultimate tensile strength of 250&#xa0;MPa. Thermo-mechanically affected zone (TMAZ) on the Al side was identified as the softest region by hardness measurement. The microstructural analysis highlighted significant grain refinement in the aluminum matrix and severe deformation in the steel region. Fracture surface analysis exhibits a mixed mode of fracture, underscoring the complex nature of the joint failure. The analysis concluded that the thin IMC layer formed in the FSW process was not detrimental to the joint’s strength, but steel fragments led to the early fracture of the Al-steel joint.</p>

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Comprehensive analysis of friction stir welding of high-temperature P22 steel and Al 5052 alloy: metallurgical mixing, mechanical properties, and failure mechanism

  • 期刊论文

  • 发表日期：

    2025年2月12日

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  • Pankaj Kaushik,
  • Dheerendra Kumar Dwivedi

摘要

This study investigates the friction stir welding (FSW) process for joining a novel combination of dissimilar materials, specifically aluminum alloy Al5052 and high-temperature–resistant P22 steel plates. This research evaluates the joint formation mechanism and the extent of metallurgical mixing in dissimilar Al-steel joints by characterizing the intermetallic layer formed at the interface. Metallographic characterization techniques such as optical microscopy, scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS), and electron backscatter diffraction (EBSD) were used for comprehensive analysis of the joint interface. This investigation demonstrated the successful formation of defect-free joints with a well-mixed interface and a thin, uniform intermetallic compound (IMC) layer, measuring 1–8 µm. Tensile testing revealed an ultimate tensile strength of 250 MPa. Thermo-mechanically affected zone (TMAZ) on the Al side was identified as the softest region by hardness measurement. The microstructural analysis highlighted significant grain refinement in the aluminum matrix and severe deformation in the steel region. Fracture surface analysis exhibits a mixed mode of fracture, underscoring the complex nature of the joint failure. The analysis concluded that the thin IMC layer formed in the FSW process was not detrimental to the joint’s strength, but steel fragments led to the early fracture of the Al-steel joint.