A2

Working Group A | Metallurgical joint

 
 
a2_spp1640

Realization of Al/high-strength steel-joints by ultrasound enhanced friction stir welding – Process and robustness, mechanical properties using destructive and innovative non-destructive test methods, microstructure, corrosion and joining zone-integrated corrosion protection

Univ. Prof. Dr.-Ing. Guntram Wagner, TU Chemnitz
Univ. Prof. Dr.-Ing. Christian Boller, IZFP Saarbrücken
Priv.-Doz. Dr.-Ing. Wolfram Fürbeth, DECHEMA Frankfurt

 
 

Abstract:

Only with hybrid construction it is possible to combine the advantages of dissimilar materials. Force-fitted or form-closed joints can be realized in an easy manner, but the strength of welded joints can be achieved rarely. However fusion welding of dissimilar materials is often impossible as a result of the different melting points. Moreover in many cases unrequested intermetallic phases occur in the weld area, whereby the attainable strength of the joints will be reduced.

 
Scheme ultrasound enhanced friction stir welding (USE-FSW)
Scheme ultrasound enhanced friction stir welding (USE-FSW)
 
 

Therefore during the first funding the ultrasound enhanced friction stir welding process (USE-FSW) was developed and applied to realize AlSi12CuNiMg/AZ80-joints. Based on microstructural investigations and determining mechanical properties of the Al/Mg-cast-joints it could be demonstrated, that this hybrid joining process is suitable to improve the technological properties of the joints significantly. Extensive innovative non-destructive investigations and detailed analysis of the corrosion behavior of the joints already enable a profound understanding of the completely novel and promising process. Furthermore, Mr. Dipl.-Ing. Benjamin Straß successfully completed his doctorate in the course of these investigations.

 
 
Light microscopic cross section images: a) FSW-joint, b) USE-FSW-joint
Light microscopic cross section images: a) FSW-joint, b) USE-FSW-joint
 
 

As part of the second funding an extension of the USE-FSW materials groups was realized. In addition to a further Mg cast alloy (AZ91) the combination of the Al alloy AlMg1SiCu and the steels C45 and DC04 were considered for the first time, whereas beside an evaluation of the fatigue behavior, an expansion of the non-destructive test methods with regard to the realization of an in-process test as well as an ongoing analysis of the corrosion behavior of the new composites were carried out.

 
 
Acoustic emission measurements by solid borne sound: a) Raw signal of measured data, b) Influence of pressure force on the sound amplitude at the faying surface, c) Influence of distance between sonotrode and faying surface on the resulting sound amplitude at the faying surface
Acoustic emission measurements by solid borne sound: a) Raw signal of measured data, b) Influence of pressure force on the sound amplitude at the faying surface, c) Influence of distance between sonotrode and faying surface on the resulting sound amplitude at the faying surface
 
 

In the final third funding period, conventional and ultrasound assisted welded aluminum and high-strength steels joints will be applied to verify the suitability of the new and innovative USE-FSW process for these material combinations. In addition, a characterization of the joining zone properties is to be carried out by means of novel non-destructive test methods and the development of a corrosion protection concept for the hybrid joints is to be implemented.

 
 
Voltapotential maps of a) FSW-joint and b) USE-FSW-joint; measured in air
Voltapotential maps of a) FSW-joint and b) USE-FSW-joint; measured in air
 
 

Publications:

2019   
  Realization of Al/Steel and Al/Mg Joints by Ultrasound Enhanced Friction Stir Welding: Mechanical Properties, Nondestructive Testing and Corrosion Thomä, M. Wagner, G. Straß, B. Wolter, B. Benfer, S. Kare Gowda, D. Fürbeth, W
In: Materials Science and Engineering Technology, 2019 (submitted)
  Hybrid Joints of die-casted Aluminum/Magnesium by Ultrasound Enhanced Friction Stir Welding (USE-FSW) Gester, A. Thomä, M. Wagner, G. Straß, B.; Wolter, B. Benfer, S. Fürbeth, W.
In: Welding in the World, 2019 (accepted)
2018   
  Ultrasound enhanced friction stir welding of aluminum and steel: Process and properties of EN AW 6061/DC04-Joints M. Thomä, G. Wagner, B. Strass, B. Wolter, S. Benfer, W. Fürbeth
In: Journal of Materials Science & Technology, Vol. 34, Issue 1, 163–172, 2018,
DOI: 10.1016/j.jmst.2017.10.022
  The Influence of Ultrasound Enhancement during Friction Stir Welding of Aluminum to Steel M. Thomä, G. Wagner, B. Strass, B. Wolter, S. Benfer, W. Fürbeth
In: Key Engineering Materials, Vol. 767, 351–359, 2018, DOI: 10.4028
  New developments in the field of ultrasound enhanced friction stir welding of dissimilar materials M. Thomä, G. Wagner, B. Straß, B. Wolter, S. Benfer, W. Fürbeth
In: 12th International Symposium on FSW, Chicoutimi, 2018
2017   
  Realization of Ultrasound Enhanced Friction Stir Welded Al/Mg- and Al/Steel-Joints: Process and Robustness, Mechanical and Corrosion Properties M. Thomä, G. Wagner, B. Straß, C. Conrad, B. Wolter, S. Benfer, W. Fürbeth
In: 146th TMS Annual Meeting, Friction Stir Welding and Processing IX, 26.02.–02.03.2017,
San Diego (CA, USA),
doi: 10.1007/978-3-319-52383-5_19
  Nondestructive Quality Inspection, Process Monitoring and Adaptation of Joint Properties in Friction Stir Welding B. Straß, C. Conrad, B. Wolter, M. Thomä, G. Wagner
In: FSWP 2017, 5th International Conference on Scientific and Technical Advances in Friction Stir Welding & Processing, 2017
  Hybrid Al/steel-joints manufactured by ultrasound enhanced friction stir welding (USE-FSW): Process comparison, nondestructive testing and microscopic analysis M. Thomä, G. Wagner, B. Straß, B. Wolter, S. Benfer, W. Fürbeth
In: IOP Conf. Series: Materials Science and Engineering 181 (2017) 012003,
doi: 10.1088/1757-899X/181/1/012003
  Hybrid joints manufactured by ultrasound enhanced friction stir welding (USE-FSW) – corrosion properties S. Benfer, W. Fürbeth, M. Thomä, G. Wagner, B. Straß, B. Wolter
In: IOP Conf. Series: Materials Science and Engineering 181 (2017) 012004,
doi: 10.1088/1757-899X/181/1/012004
2016   
  Ultrasound assisted Friction Stir Welding of Al/Mg-hybrid joints: process analysis, comparison of microstructural, mechanical and corrosive characteristics M. Thomä, G. Wagner, B. Straß, C. Conrad, B. Wolter, S. Benfer, W. Fürbeth
In: 11th International Symposium on FSW, Cambridge, 2016
  Manufacturing and corrosion properties of ultrasound supported friction stir welded Al/Mg-hybrid joints S. Benfer, B. Straß, G. Wagner, W. Fürbeth
In: Surface and Interface Analysis, Vol 48, S. 843-852, 2016,
doi: 10.1002/sia.5871
  Investigations on the corrosion properties of ultrasound supported friction stir welded hybrid joints S. Benfer, W. Fürbeth, B. Straß, M. Thomä, G. Wagner
In: 67th Annual Meeting of the International Society of Electrochemistry, Den Haag (Niederlande), 2016
  Herstellung und Korrosionseigenschaften von durch ultraschallunterstütztes Rührreibschweißen erzeugten Al/Mg-Hybridverbunden S. Benfer, W. Fürbeth, B. Straß, M. Thomä, G. Wagner
In: GfKORR-Arbeitskreis Korrosion und Korrosionsschutz von Aluminium und Magnesium, Jülich, 2016
  Recent Developments for Ultrasonic-Assisted Friction Stir Welding: Joining, Testing, Corrosion – an Overview M. Thomä, G. Wagner, B. Straß, C. Conrad, B. Wolter, S. Benfer, W. Fürbeth
In: IOP Conf. Series: Materials Science and Engineering 118 (2016) 012014,
doi: 10.1088/1757-899X/118/1/012014, 2016
  Aktuelle Entwicklungen beim ultraschallunterstützten Rührreibschweißen (US-FSW) – Verfahren, Verbundeigenschaften, Mikrostrukturanalyse der Verbunde M. Thomä, G. Wagner, B. Straß, C. Conrad, B. Wolter
In: 7. HZG Workshop „Rührreibschweißen und verwandte Verfahren“, Geesthacht, 2016
  Untersuchung der Korrosionseigenschaften von AL/MG-FSW und Al/Mg-US-FSW-Verbunden S. Benfer, W. Fürbeth, B. Straß, M. Thomä, G. Wagner
In: 7. HZG Workshop „Rührreibschweißen und verwandte Verfahren“, Geesthacht, 2016
2015   
  Ultraschallunterstütztes Rührreibschweißen von Al/Mg-Verbunden: Prozessanalyse, mikrostruktureller, mechanischer und korrosiver Eigenschaftsvergleich B. Straß
In: Dissertation TU Kaiserslautern, 2015
  Realization of Metal Hybrid-Joints by Ultrasound Supported Friction Stir Welding – An Innovative Method to Improve the Joint Quality B. Straß, G. Wagner
In: Friction Stir Welding and Processing VIII, 144th TMS Annual Meeting, Orlando (FL, USA), 2015
2014   
  Realization of Al/Mg-Hybrid-Joints by Ultrasound Supported Friction Stir Welding B. Straß, G. Wagner, D. Eifler
In: Materials Science Forum, Vol. 783-786, S. 1814-1819, 2014
  Realization of Al/Mg-Hybrid-Joints by Ultrasound Supported Friction Stir Welding – Mechanical Properties, Microstructure and Corrosion Behavior B. Straß, G. Wagner, C. Conrad, B. Wolter, S. Benfer, W. Fürbeth
In: Advanced Materials Research Vol. 966-967, S. 521-535, 2014
  Corrosion investigations of ultrasound supported friction stir welded Al/Mg-hybrid joints S. Benfer, B. Straß, G. Wagner, W. Fürbeth
In: Eurocorr 2014, Pisa (Italy), 2014
  Ultrasound Supported Friction Stir Welding of Dissimilar Materials B. Straß, G. Wagner, D. Eifler
In: 10th International Friction Stir Welding Symposium, Peking (China), 2014
  Ultrasound Supported Friction Stir Welding of Al/Mg-Hybrid-Joints B. Straß, G. Wagner, D. Eifler
In: Euro Hybrid – Materials and Structures, Stade, 2014
2013   
  Joining of Al Alloys to Mg Alloys by Ultrasound Supported Friction Stir Welding (US-FSW) B. Straß, G. Wagner (V), D. Eifler
In: International Conference on Processing & Manufacturing of Advanced Materials (THERMEC), Las Vegas (Nevada, USA), 2013
 

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