Table 1.
Chemical composition of AA1060/Q235 clad plate and filler materials (wt.%).
Table 2.
Mechanical properties of AA1060/Q235 clad plate and filler materials.
Fig 1.
Welding procedure for the Al/steel clad plates: (a) groove dimensions, (b) welding of the steel substrate, (c) groove milling after steel-side welding, (d) FSW of the aluminum cladding.
Table 3.
Welding parameters for TIG and SMAW (steel substrate).
Fig 2.
FSW tool geometry and dimensions.
Table 4.
FSW welding parameters.
Fig 3.
Surface appearance of a representative FSW weld (pin length = 4.0 mm).
Fig 4.
Advancing-side weld cross-sections (SEM) for pin lengths of 3.6–4.4 mm: (a) 3.6 mm, (b) 3.8 mm, (c) 4.0 mm, (d) 4.2 mm, (e) 4.4 mm.
Fig 5.
Effect of pin length on interface offset and effective thickness of the steel region (ETs).
Fig 6.
Microstructure at the Al/steel interface for pin lengths of 3.6–4.4 mm: (a) 3.6 mm, (b) 3.8 mm, (c) 4.0 mm, (d) 4.2 mm, (e) 4.4 mm, with (f) showing a magnified view of the steel-side region adjacent to the interface for the 4.4 mm joint.
Table 5.
Chemical composition and possible phases at the points marked in Fig 6c1.
Fig 7.
SEM micrographs (a1–d1) and corresponding EDS line scans (a2–d2) across the Al/steel interface for different pin lengths: (a1, a2) 3.8 mm, (b1, b2) 4.0 mm, (c1, c2) 4.2 mm, (d1, d2) 4.4 mm.
Fig 8.
XRD pattern of the joint cross-section for a pin length of 4.2 mm.
Fig 9.
Tensile strength, effective steel thickness (ETs), and IMC layer thickness as functions of pin length.
Fig 10.
Microhardness distribution across the joint for various pin lengths.
Fig 11.
Stress-strain curves for different pin lengths.
Fig 12.
Fracture surface morphology of the steel region adjacent to the interface for different pin lengths: (a) 3.8 mm, (b) 4.0 mm, (c) 4.2 mm, (d) 4.4 mm.