Mass reduction of automotive body structures is a critical part of achieving reduced CO2 emissions in the automotive industry. There has been significant work on the application of ultra high strength steels and aluminum alloys. However, the next paradigm is the integrated use of both materials, which creates the need to join them together. Friction stir forming is a new environmentally benign manufacturing process for joining dissimilar materials. The concept of this process is stir heating one material and forming it into a mechanical interlocking joint with the second material. In this research the process was experimentally analyzed in a computer numerical controlled machining center between aluminum and steel work pieces. The significant process parameters were identified and their optimized settings for the current experimental conditions defined using a design of experiments methodology. Three failure modes were identified (neck fracture, aluminum sheet peeling, and bonding delamination i.e. braze fracture). The overall joint structure and grain microstructure were mapped along different stages of the friction stir forming process. Two layers were formed within the aluminum, the thermo-mechanical affected zone that had been deformed due to the contact pressure and angular momentum of the tool, and the heat affected deformation zone that deformed into the cavity.
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ASME 2014 International Manufacturing Science and Engineering Conference collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
June 9–13, 2014
Detroit, Michigan, USA
Conference Sponsors:
- Manufacturing Engineering Division
ISBN:
978-0-7918-4581-3
PROCEEDINGS PAPER
Dissimilar Material Joint Strength and Structure for Friction Stir Forming Process
Kenneth A. Ogata,
Kenneth A. Ogata
University of Hawaii at Manoa, Honolulu, HI
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Sladjan Lazarevic,
Sladjan Lazarevic
University of Hawaii at Manoa, Honolulu, HI
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Scott F. Miller
Scott F. Miller
University of Hawaii at Manoa, Honolulu, HI
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Kenneth A. Ogata
University of Hawaii at Manoa, Honolulu, HI
Sladjan Lazarevic
University of Hawaii at Manoa, Honolulu, HI
Scott F. Miller
University of Hawaii at Manoa, Honolulu, HI
Paper No:
MSEC2014-4044, V002T02A076; 7 pages
Published Online:
October 3, 2014
Citation
Ogata, KA, Lazarevic, S, & Miller, SF. "Dissimilar Material Joint Strength and Structure for Friction Stir Forming Process." Proceedings of the ASME 2014 International Manufacturing Science and Engineering Conference collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. Volume 2: Processing. Detroit, Michigan, USA. June 9–13, 2014. V002T02A076. ASME. https://doi.org/10.1115/MSEC2014-4044
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