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Friction weldability of aluminium alloys to carbon steel

To save component weight, valuable material resources and energy, recent years have seen a growing need to have welded joints produced from dissimilar materials. The authors are presently engaged in a research programme on weight reduction of structural components and friction welding of pipe joints produced from aluminium alloy/ steel dissimilar materials.' When friction welding is used to produce pipe joints, the base metal tends to buckle more than when solid bar joints are friction welded, the problem therefore being the difficulty of applying heavy friction welding pressure. An advantage, on the other hand, is that the friction speed remains constant right across the friction surface region as a whole. However, no comparative research data on the friction weldability of pipe and solid bar joints produced from dissimilar materials are available, and data relating to friction welding being applied for aluminium alloy to steel solid bar joints are only available for a number of individual grades of materials.' No systematic research whatever has yet been conducted. To clarify the strength difference between pipe joints and solid bar joints, this research study describes an investigation of the joint strength of solid bar friction-welded joints produced from nine widely marketed grades of wrought aluminium alloys and carbon steel. The data obtained for solid bars are compared with the performances of pipe joints reported elsewhere.