The microstructure and mechanical properties of aluminum/steel welded joint with Ni foil interlayers by FSLW

AbstractFriction stir lap welding experiments between 6061 aluminum alloy plate and DP590 dual-phase steel plate were carried out. The effects of welding parameters and addition of Ni foil interlayers with different thickness on the microstructures and mechanical properties of the lap joints were investigated. The shear strength of the joint reached the maximum value of 6597 N and showed a mixed ductile-brittle fracture mode when the welding speed, the rotating speed and the thickness of the Ni foil intermediate layer were set to 100 mm/min, 900 rpm and 0.3 mm, respectively. A certain amount of beneficial plastic AlNi and FeNi3 intermetallic compounds are formed through the reaction of Al, Fe and Ni at the aluminum alloy/steel interface.Keywords: Aluminum alloydual-phase steelfriction stir lap weldingNi foil interlayermicrostructuremechanical property AcknowledgementsThanks to Yuxin Peng, Xian Li, Xiaokun Shen, Yifan Zhao for their experimental help and comments on this contribution.Disclosure statementThe authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.Additional informationFundingThis work was supported by the Special Funds for Guiding Local Scientific and Technological Development by the Central Government of China [No. 2019ZYYD015], the Doctoral Research Start-up Fund of Hubei University of Technology [XJ2021009402], the Youth Talent Project of Science and Technology Research Program for Education Department in Hubei Province [No. Q20311412] and the Educational Reform Research Project for Postgraduate Students of Hubei University of Technology [No. 2022050].