Friction welding of Al-Al, Al-steel, and steel-steel samples

Friction welding of Al-Al, Al-steel, and steel-steel studs is compared. Transient heat generation and temperature rise during the welding process were modeled. Tensile tests and microhardness measurements across the weld zone were carried out. The metallurgical changes in the heat-affected zone were examined by SEM. Temperature rise at the interface plane was computed and related to weld properties. The affecting parameters on weld quality were identified by statistical analysis. Results show that interaction of weld parameters significantly affect yield, tensile, and breaking strength, and the heat-affected zone on the Al side is wider for Al-steel welds.