The effect of interlayers on dissimilar friction weld properties

The influence of silver interlayers on the metallurgical and mechanical properties of dissimilar aluminium alloy/stainless steel friction welds are investigated.; An elastic contact model is proposed that explains the conditions at and close to the contact surface, which produce Al₂O₃ particle fracture in dissimilar MMC/AISI 304 stainless steel friction welds.; Intermixed (IM) and particle dispersed (PD) regions are formed in Ag-containing dissimilar friction welds. These regions form very early in the joining operation and both contain Ag₃Al. Therefore, an interlayer (Ag) introduced with the specific aim of preventing Fe_xAl_y compound formation in MMC/AISI 304 stainless steel friction welds promotes the formation of another intermetallic phase at the bondline. Since IM and PD regions are progressively removed as the friction welding operation proceeds thinner intermetallic layers are produced when long friction welding times are applied. This type of behavior is quite different from that observed in silver-free dissimilar MMC/AISI 304 stainless steel welds.; Nanoparticles of silver are formed in dissimilar MMC/Ag/AISI 304 stainless steel welds produced using low friction pressures. Nanoparticle formation in dissimilar friction welds has never been previously observed or investigated.; The introduction of silver interlayers decreases heat generation during welding, produces narrower softened zone regions and improved notch tensile strength properties. All research to-date has assumed per se that joint mechanical properties wholly depend on the mechanical properties and width of the intermetallic layer formed at the dissimilar joint interface. However, it is shown in this thesis that the mechanical properties of MMC/AISI 304 stainless steel joints are determined by the combined effects of intermetallic formation at the bondline and softened zone formation in MMC base material immediately adjacent to the joint interface. A methodology for calculating the notch tensile strength properties of dissimilar friction welds is presented and is based on a combination of FEM with a ductile failure criterion. There is excellent correspondence between actual and calculated joint strength results.