A Novel Lap-Butt Joint Design for FSW of Aluminum to Steel in Tee-Configuration: Joining Mechanism, Intermetallic Formation, and Fracture Behavior

The development of new joint configurations suitable for dissimilar materials enables a wider range applications and allows an accelerated replacement traditional structural construction by lightweight materials. T-configuration is configuration that has not been sufficiently studied use with materials, especially when created using the friction stir welding (FSW) process. In this study, combined lap/butt design was introduced implemented, seeking to create T-joint between aluminum steel. Characterization joints showed FSW could be successfully used join steel in T-configuration. formation intermetallic bonds kissing carefully analyzed, their contribution fracture behavior during loading skin stringer directions studied. Finite element simulation determine stress state at interface loading. characterization results intermetallic, as indicator metallurgical bonding, formed special features are observed pattern material flow. fractography images major impact on fracture. present study can effectively fabricate joints, taking into account condition.