International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Joining of AISI 1040 Steel to 6082-T6 Aluminium

Alloy by Friction Welding
CH. Muralimohana,1 , S. Haribabub,2, Y. Hariprasada Reddyb,3 V. Muthupandi a,4 , K. Sivaprasad a,5
a

Department of Metallurgical and Materials Engineering, National Institute of Technology Tiruchirappalli 620015,
Tamilnadu, India
1

muralicheepu@gmail.com, 4vmuthu@nitt.edu, 5ksp@nitt.edu

Department of Mechanical Engineering, Sri Venkatesa Perumal College of Engineering and Technology Puttur 517583,
Andhra Pradesh, India
2

haribab204513@gmail.com, 3prof.yhpr@gmail.com

Abstract AA 6000 series are being used as automotive

applications due to the competence to be strengthened by
factitious aging subsequently forming. The joining of aluminium
to itself as well as other materials becomes increasingly
important. Joining of aluminium to steel offered distinctive
metallurgical and mechanical properties and recognition of
suitable joining methods are challenging. This paper describes a
continuous drive friction welding of 6082-T6 aluminum alloy to
AISI 1040 steel via several processes parameters. The influence
of friction time and forging pressure on mechanical and
metallurgical properties were evaluated. Results of these analyses
showed that strength of the welded joints on the order of
220 MPa. The tensile strength made little difference by a rise in
friction time under constant forging pressure. However, at the
welds made under constant friction time, the ultimate tensile
strength of the welds increased through gradual rise in forging
pressure. Hence, the forging pressure acting a major role over
the influencing of other two major parameters such as friction
pressure and friction time on strength of the welds.
Microstructural characterization was done by using optical
microscopy and scanning electron microscopic analysis. The
elemental composition of welds was analyzed by energy
dispersive X-ray spectroscopy technique. The presence of Al-Fe
chemical species were characterized via a thin layer of transition
zone on bond lines and the significance of percentage of
compositions seems related to the Fe2Al5 and FeAl intermetallic
compounds. The tensile fracture of the welded joint occurred in
6082-T6 aluminium side near the interface. The characterization
of fracture surfaces reveals the pattern of dimples structure.
Keywords Aluminium, steel, friction welding, dissimilar metals,
mechanical properties, microstructural characterization

I.

INTRODUCTION

Friction welding process is a solid state welding

technique; it has been developed and achieved to more
advanced state encompassed by other welding methods. The
importance of this friction welding method has been expanded
the prominence in the manufacturing industry. The dominance
of friction welding influencing the most effective welding

method of analogous and divergent metals for the maximum

inexpensive and higher production rates and greatly efficient
joints, higher in emulate, very less fabrication time and low
vitality input [1]. The utmost significant specifications in
friction welding are friction pressure, friction time, forging
pressure, forging time and rotating speed [2]. The parameters
impacting friction welding has been deliberated antecedently
[3]. Friction welding processes experienced to heating of
welding samples to get the anticipated temperatures at the
faying faades with the effect of friction, developed by
rubbing weld surfaces of the joining parts.
The joining of contradictory materials passes the probable
to exploit the benefits of dissimilar materials repeatedly given
that distinctive elucidation to many industrial applications [4].
The main object to join dissimilar metals is owing to the
amalgamation of beneficial properties of mechanical and
microstructure of one object and either extensive corrosion
resistance or low specific weight or virtuous properties of
electrical of the other substantial metals [5, 6]. In recent years,
the joining processes for dissimilar materials demanding
especially in automobile industry outstanding the saving
weight of vehicle accessories and body structures. It is
essential to magnify the usage of trivial structures in
automobile industries has enlarged attention in the practice of
both aluminium (Al) and carbon steels as important
construction components. Though, the cost of aluminium
related to carbon steels limits its applications intended for
many industries. For instance a result of this, it is necessary to
produce joints between aluminum and steel. However, it is
very difficult to produce a reliable joint because of their poor
metallurgical compatibility and mismatch in mechanical
properties. Conventional fusion welding cannot be feasible to
make a reliable joint due to the occurrence of stress
concentration, chemical segregation and formation of
secondary intermetallic phases.
Literature reports that experiments had overseen on the
joining techniques of steel to aluminium ranges from
conventional welding methods to sold state welding
procedures such as gas metal arc welding [7], explosive

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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

welding [8], solid state welding methods such as friction stir

welding techniques [9] and vacuum diffusion bonding
processes [10]. Many of the studies on friction welding of
similar materials available, but the challenging in joining of
dissimilar materials studied by Murti et al. on friction welding
[11]. They were attentive a practical and theoretical studies
over optimization of processes parameters in joining of
dissimilar metals by friction welding technique. The
investigation has done by Yilbas et al. [3] on physical and
microstructural characterization on friction-welded structural
steel-aluminium alloys, and aluminium to copper. The
behavior of friction welding on aluminium and its alloys were
investigated by Yilbas and his co-workers [12]. The
examinations of microstructure evaluation on 7075 Al with
friction-stir process [13]. The characteristic investigation of
Fukumoto et al. [14] on amorphization processes allying Al
alloy and stainless steel (SS) by friction welding process. The
strength of the aluminium alloys with the carbon steel welds
impacts by some of the inadequacies existed being microcracks, weld pores, unwanted secondary phases and
alterations. The character of a weld is comprehensively
depending on the proper optimized parameters, these will
establish the metallurgical alterations and tension strength of
the welded components. One of the friction welding parameter
such as friction time is influencing other parameters, the
gradual increment in this, a wide transmission area next to the
weld line with presence of secondary particles. For low
friction pressure, short friction times with less in forging
pressures the weld in fragile at the joint interface and these
leads to the formation of inappropriate bonds with the
presence of voids. To accomplish maximum efficient joints
the friction time necessary to maintain as low as required,
although the friction and forging pressure can be taken for
higher ranges [15]. Therefore, the aim of the present
experimentations is to examine the characterization of
metallurgical properties and changes in mechanical properties
varying with process parameters of friction welded joints of
6082-T6 aluminium to AISI 1040 steel.
II.

machined on lathe to required size. In this experiment, the

friction welding parameters such as friction time, forging
pressure and friction pressure are varied while the speed of the
rotating part per minute and forging time held at constant.
Parameters employed in performing the various trails are
given in Table 3. After completion of the welding the sample
taken out from the machine and tensile sample is prepared as
per ASTM-E8 standard. The specimens for V-notch impact of
55x10x10 mm and V-notch is prepared at weld interface of 2
mm depth and 45 angle. The toughness of the resulted welds
is recorded at with increase in forging pressure and increase in
friction time. The metallographic techniques were applied for
all the welds made by different process parameters. The
evaluation of joint strengths was conducted after making
joints immediately performed a drop test for all the welds at
various welding parameters.
Microstructural observations of the as-received rods and
weld interfaces were accomplished via optical metallography
technique and scanning electron microscope (SEM) analysis.
Frictions welding of the sectioned transverse welds were
prepared for microstructural observation as per standard
metallography procedures. Energy dispersive X-ray
spectroscopy (EDS) studies were executed to confirm the
intermetallic formation and elemental distribution at the weld
interface. Microhardness survey was performed at the bond
interface of the joints and the zones immediate both the steel
and aluminium alloy by with a digital microhardness tester. A
load of 300 g was applied for 10 s for 1040 steel, and 100 g
for 10 s for aluminium alloy. The tensile failure regions of the
resulted joints existed examined using SEM for the fracture
location and the mode of failure.
Table I
CHEMICAL COMPOSITION (Wt.%) OF BASE MATERIALS
AA
6082
AISI
1040

EXPERIMENTAL STUDIES

In this study, the materials AISI 1040 steel and AA 6082T6 aluminium rods of diameter and length were machined in
the dimensions of 10 mm and 80 mm respectively. The X-ray
fluorescence (XRF) spectroscopy analysis has made to
resolute the elemental admixture of the parent materials, as
shown in Table 1. The base materials were tested for the
assessment of physical properties, as shown in Table 2. The
continuous drive friction welding method was used to perform
the friction welding joints. The welds which were made
between AISI 1040 steel and AA 6082- T6 aluminium by
friction welding, each deformation resistance differs greatly,
in that the aluminium base metal deforms by plastic
deformation during joining. The aluminum alloy maintained
as a rotating part and 1040 steel sample positioned in a static
condition. Resulted welds obtained the circular flash diameter
on Al side is larger than the steel side, so that the flash was

ISBN 978-93-80609-17-1
1345

Si
0.71.3
C
0.360.45

Fe

Cu

0.4

0.1

0.04

0.05

Mn

Mg

0.51.1
Mn
0.60.9

0.61.2
Si
0.050.35

Zn

Ti

Cr

Al

0.2

0.1

0.22

Bal

Ni

Mo

Cr

Fe

Bal

Table II
MECHANICAL PROPERTIES OF MATERIALS USED IN THE
EXPERIMENT

AA 6082

YS
(MPa)
215

UTS
(MPa)
240

Elongation
(%)
11

Hardness
(Hv)
105

AISI 1040

348

510

28

152

Samples

Table III
FRICTION WELDING CONDITIONS
Forging
Pressure
(p1) MPa

Friction
Time (t1)
sec

Friction
Pressure
(p2) MPa

Forging
Time (t2)
sec

RPM

140200

18

60120

1500

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

III.
A.

REULTS AND DISCUSSIONS

Microstructure Characterization

The resulted friction welded joints evinces the existence

of weld flash of mixed material owing to severe plastic
deformation with frictional heat and movement of aluminium
in the interface of heterogeneous welds. Joint flash formed at
the aluminium side while the steel side is not externally
changed. Fig. 1 shows the macro structural features of the
interfaces with increasing upset pressure. With an increase of
forging pressure, the amount of flash increases and the shape
of the flash tilts toward aluminium from its original radial
direction. The center of faying surfaces has a flat shape
regardless of forging pressure the periphery of joint is a
mechanical mixer of aluminium and steel. This is due to the
periphery of joint is faster than the center of the joint, so the
frictional heat of the periphery of the joint is larger than the
central part. Consequently, at the periphery of the joint plastic
flow is easier than in central part. This produces an increase of
surface area and is deliberated to contribute to joint strength
increases [16].

The microstructure of the base material 6082-T6

aluminium alloy is depicted in Fig. 2, with the insubstantial
grains formed in equiaxed structure. Microstructure details
existed studied at the aluminiumsteel interfaces. In all the
joints due to the effect of high rotational speed combined with
friction pressure and upset pressure, aluminium grains close to
the interface are mechanically deformed and recrystallized as
fine equi-axed grains. With an increase in temperature due to
friction the yield strength of aluminium decreases and the
atomic diffusivity increases which results in more interfacial
deformation and facilitates the metallurgical bonding. The
presence of deformed grains in steel indicates that
deformation is not confined to aluminium because of its low
strength and melting point but steel is also subjected to some
amount of deformation in the region close to the interface. It
can be seen from Fig. 3 SEM image of the Alsteel interfaces.
The SEM images reveal good bonding along Alsteel
interfaces of the friction welded joints, and interfaces are free
from discontinuities and micro-cracks. The interface between
aluminium and steel is characterized by very thin diffusion
transition layer was revealed. The transition layer thickness
increases with increasing friction time. The elongate be
influenced by of the transition layer wideness owing to the
development of weld lines are instigated by diffusion is entails
the square root of the friction time [15]. The transition layer
performs through homogeneous and seems with a pale
overcast divergence.

Fig. 1 Macrograph showing the transverse section of the weld with interface

Fig. 3 Scanning electron microstructure of the aluminiumsteel weld interface

Fig. 4 EDS spot scan spectrum of the Alsteel weld interface

Fig. 2 Optical microstructure of the 6082 Al alloy base material

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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Fig. 4 shows the EDS spot analyses were made across

the sliced transverse sections of the optimal welds produced
with friction pressure of 90 MPa, forging pressure p2180
MPa and friction time t14 s. The EDS energy spectrum
Fig. 4 of weld interface as results of chemical analysis made at
different locations are recorded. The average chemical
composition of elements are Al is ~52.860.5 at.% and Fe is
~46.250.8 at.%. It is worth noting that establishment of the
chemical anatomy at the Alsteel interface; the AlFe
compound diagram indicates the possibility of presence of
FeAl and Fe2Al5 intermetallic phases [17]. The formation of
these secondary species leads to degradation in the tensile
properties.
B.

tensile strength of the welds enhanced slightly through an

augment in forging pressure overt the 160 MPa. Whereas the
amount of upset increased constantly with increasing forging
pressure, in this regard forging pressure of 160 MPa does not
contribute to tensile strength elevation regardless of friction
time. Therefore, the optimal weld strength of 220 MPa
attained at friction time t14 sec, and forging pressure p2180
MPa. Though, in all the joints tensile fracture occurred at
aluminum side nearer to weld interface with ductile mode.

Mechanical Properties

The micro-hardness survey was conducted across the

Alsteel joint interface covering base material and abutting
weld material affected by frictional heat is demonstrates in
Fig. 5. It can be envisage from results showing eventually the
analogous tendency in hardness distribution away from
interface. Whereas, in interface area it deliberates hardness
profile slightly strengthens with escalate in forging pressure.
The microstructural tendency counsel that inadequate friction
pressure and steep forging pressures excel to utmost hardness.
These changes caused due to the slighter frictional heat input
accessible at the interior resulting outrageous strain hardening
effect. The highest hardness value on aluminium side near the
weld lines is directly associated to the microstructure
crystallized in the weld as a result of high density dislocations
during extensive plastic deformation. However, there is no
appreciable increase in hardness in 1040 steel side equated to
original hardness of the parent material representing that strain
hardening is less and the extent of deformation is limited on
steel compared to aluminium. The peak hardness recorded at
Al/steel interface can be attributed to the formation of
intermetallic compounds of AlFe and microstructural
formation.
Fig. 6 shows the changes tensile strength and amount of
upset with increasing in forging pressure. The resulted

Fig. 5 Hardness profile showing the variation in hardness at center and

periphery regions recorded at the joint interface

Fig. 6 Variations of tensile strength with forging pressure (p2)

Fig. 7 shows the variation in tensile strength with

friction time for each forging pressure. When the forging
pressure is 140 MPa, which is the lowest pressure in the
present experimentation, thought the additions of friction
time, the strength of friction welded joint is dispirited. That is,
however the thermal degradation region increase with friction
time, the lowest pressure cannot discharge thermal
degradation region from the interface completely [16]. Hence,
it is considered that the effect of welding parameters such as
forging pressure affected distantly on tensile strength plays a
major role beyond the other parameters are friction pressure
and friction time, which is mainly under the control of forging
pressure.

Fig. 7 Effect of friction time on tensile strength at constant forging pressures

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International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Impact strength results inveterate the influence of

temperature on welds. The toughness of the welds varying
through different welding processes and with varies
temperatures. Hence, the toughness is depleting with
inappropriate assortment of process parameters. The inflated
forging pressure ameliorates in associating the bonding of the
joints. The experimental impact test results are increased with
forging pressure and the maximum strength of 36 J attained at
forging pressure-160 MPa, friction pressure100 MPa and
friction time2 sec. Impact strength is decreasing with
enhancement of friction pressure due to the heat development
at the bonding area is affected on grain coarsening. Toughness
and tension strengths intensifying with amplifying the forging
pressure, and this resulting due to equi-axed granulated grain
pattern with exorbitant strain hardening effect on heat affected
zone and bond lines.
C.

2.

3.

4.

5.

ACKNOWLEDGMENT
The authors would like thank materials joining laboratory
IIT Madras for permission to use the friction welding facility.
REFERENCES

Fracture Surface Analysis

[1]

Failure occurred at aluminium base metal is adjacent to

the weld interface for all trails. To investigate the etiquette of
the fracture was characterized by scanning electron
microscopy and the exhibited fracture graphs are materialized
in Fig. 8. The SEM fractured graphs propounded that the
fracture is assorted manner. Some of the fracture morphology
depicted that the tensile shearing surface due to the effect of
pulling test. The mode of failure is purely ductile in nature
with formation of dimple structure.

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[9]

[10]
Fig. 8 SEM fracture showing the morphology of joint with ductile failure
[11]

IV.

SEM fracture surfaces it can be perceived that the

fracture morphology located with dimples and
emerges to be pliable nature of failure.
The v-notch impact test established that, the impact
values of specimens are virtually same value that for
the base material.
Microhardness test exhibited that, the pattern of
hardness values increased with forging pressure. The
change in hardness value at the weld demonstrated
the imputed to the strain hardening effect.
EDS analysis showed that the presence of FeAl and
Fe2Al5 intermetallic phases.

CONCLUSIONS

AA 6082T6 aluminium to AISI 1040 steel was

effectively accomplished by friction welding processes. The
alterations in microstructure through welding of bonded
specimens were studied in circumstance. The effects of
welding process parameters on microstructural interchanges,
microhardness and tension tests of friction welded joints were
explored and the reciprocity at metallurgical structures and
fracture durability were disputed. The below are the some of
the existed conclusions in the study.
1. The strength of the welds diminished with an
enhancement of heating time for weld. On the whole,
welds unveiled that the joint strength commensurate
with parent metal.

[12]

[13]

[14]

[15]

[16]

[17]

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