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DOE OSTI2021

Solid-State Joining of Magnesium Sheet to High-Strength Steel

Increasing the use of lightweight materials and implementing enabling manufacturing technologies are the two primary paths toward automotive weight reduction. In many situations, the ability to substitute light weight material requires a need to attach and join light weight material to existing steel substructures requiring dissimilar joining technologies. Dissimilar joining methods currently available in cost range for high volume automotive manufacturing face multiple challenges. The problem is exacerbated in the case of Magnesium alloy to steel joints because of their highly dissimilar nature and lack of mutual miscibility. Additionally, Magnesium’s poor room temperature ductility complicates the use of point fastening technologies. Two emerging solid-state joining technologies Friction Stir assisted Scribe welding (FaST) and Ultrasonic Welding (USW) that employ large amount of plastic deformation at the interface were used to investigate, develop, and understand dissimilar joints between Magnesium Alloy to DP590 Steel. Various process responses including interface temperatures, process forces, strain fields were captured during the development of the welding process. Variety of welded samples were tested and characterized to understand the relationship between welding conditions and joints microstructure and mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A review of technologies for welding magnesium alloys to steels

Here we review various state-of-the-art methods for welding magnesium alloys and steels using different joint configurations. Microstructural characterizations indicate that four microstructures may form at the Mg/steel interface after welding: unwelded gap, metal oxides, solid solutions, or intermetallic compounds. Reaction products at the Mg/steel interface vary with different welding methods, alloying elements in base materials, interlayers or coatings applied, and preparations of base material before welding. Regarding mechanical property characterization, (a) lap tensile shear testing for lap-welded and spot-welded joints, (b) tensile testing for butt-welded joints and (c) fatigue properties of lap-welded and spot-welded joints are summarized and compared, separately. Reaction products at the Mg/steel interface are correlated with mechanical properties. Finally, ways to enhance Mg/steel joint strength, such as introducing interlocking features during friction stir lap and butt welding, are discussed.

Wang, Tianhao↗

DOE OSTI2021

Stationary Shoulder Friction Stir Assisted Scribe Technique for Dissimilar Joining

We report on implementation of a stationary shoulder in dissimilar joints of Al-steel and Al-carbon fiber reinforced polymer (CFRP) using friction stir assisted scribe technology (FaST ). Viable joint strength similar to that with the conventional FAST process was demonstrated in Al-steel. A significant improvement in as-welded surface roughness for both Al-steel and Al-CFRP cases was achieved by using stationary shoulder. Interrupted lap shear tests performed on Al-steel joints and a corresponding computational model indicate the joint failure typically occurs in Al sheet via a crack tip that originates at the steel hook tip on the loading side. A similar fracture path was observed in an Al-CFRP joint.

Das, Hrishikesh↗

DOE OSTI2023

In-situ measurement and control of the tool-workpiece interface temperature during friction stir processing of 304/304L stainless steel

Friction stir processing of 304/304L stainless steel is an area of interest for repair of spent nuclear fuel canisters. To enable repair without canister deflection or fracture, it is necessary to define the limitations for the depth of the processing zone which will be critically dependent on the thermal history of the material. Here, this work provides the first direct measurement of the interface temperature for friction stir processing of steel. The measured temperature is in the range of 850–1050 °C which is 20–30 % higher than previously reported values. Notably, the peak temperature occurs at the pin tip which is attributed to a higher sticking fraction and subsequently higher strain rate near the tool axis of rotation. Furthermore, a clear correlation between the temperature, grain size, and hardness is established within a single weld nugget and across different processing conditions. In the future, this data may lead to improved process modelling through direct validation and allow for property optimization through direct microstructure control.

304 stainless steel↗