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1773937 
Journal Article 
Dissimilar friction welding of 6061-T6 aluminum and AISI 1018 steel: Properties and microstructural characterization 
Taban, E; Gould, JE; Lippold, JC 
2010 
1 
Materials & Design
ISSN: 0264-1275
EISSN: 1873-4197 
31 
5 
2305-2311 
WOS:000276153600004 
Joining of dissimilar materials is of increasing interest
for a wide range of industrial applications. The automotive industry, in particular, views
dissimilar materials joining as a gateway for the implementation of lightweight materials.
Specifically, the introduction of aluminum alloy parts into a steel car body requires the
development of reliable, efficient and economic joining processes. Since aluminum and steel
demonstrate different physical, mechanical and metallurgical properties, identification of proper
welding processes and practices can be problematic. In this work, inertia friction welding has
been used to create joints between a 6061-T6 aluminum alloy and a AISI 1018 steel using various
parameters. The joints were evaluated by mechanical testing and metallurgical analysis.
Microstructural analyses were done using metallography, microhardness testing, scanning electron
microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray elemental mapping, focused ion beam
(FIB) with ultra high resolution SEM and transmission electron microscopy (TEM) in TEM and STEM
modes. Results of these analysis first suggested that joint strengths on the order of 250 MPa
could be achieved. In addition, failures were seen in the plasticized layer on the aluminum side
of the joint. Further, bond lines were characterized by a thin layer of formed Al-Fe
intermetallic. This intermetallic layer averaged roughly 250 nm thick and compositionally appears
related to the FeAl and Fe(2)Al(5) phases. (C) 2009 Elsevier Ltd. All rights reserved. 
Dissimilar welding; Aluminum; Steel; Microstructural characterization