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Introduction

Recent technological advances havenecessitated the development of new ma-terials as well as new methods for joiningthem. An example of such a material is themetal matrix composite (MMC), which isessentially a structure consisting of a com-bination of two or more macro compo-nents that dissolve within one another.Metal matrix composites, which both havea high elastic modulus of ceramic and highmetal ductility, are used with conventionalmetallic materials in fields such as aircraftand aerospace engineering, as well as de-fense and automotive industries. Ratiossuch as strength/weight and strength/den-sity play an important role in metal matrixcomposites, and in so doing, they addsomething novel and innovative to thescope of structural materials (Refs. 1, 2).

As the demand for these new materialsgrows, studies related to the productionand mechanical properties of compositematerials have become a focus of re-

search. Additionally, many studies aboutthe production processes and estimationproperties for this kind of material arecontinuing. Furthermore, investigationson practical applications of secondary pro-cessing technologies (such as machining,joining, plastic forging, etc.) are also re-markable. Currently, research related tojoining science and technology for themetal matrix composites (in particular,aluminum alloy matrix composites) alsobecomes one of the key-point issues fortheir potentially successful engineeringapplications.

There are still many problems withjoining metal matrix composite materials(in particular, for the ceramic-reinforcedaluminum alloy matrix composites) used

in fusion welding processes (Ref. 3).In the welding stage, existence of the

difference between the chemical potentialof the matrix and reinforcement materialshows there is no thermodynamic balancebetween the two. Under the welding con-ditions, undesirable chemical reactionsoccur between the aluminum and SiC. Theresult is an inferior-quality welded joint.

Uncontrolled solidification is anotherproblem that one may encounter in fusionwelding. This process occurs in the weld-ing pool as cooled down; that is, the rein-forcement phases such as SiC particulateswere strongly rejected by the solidificationfront and normal solidification processesof the welding pool were broken down thatconsequently led to microsegregation orinhomogeneous distribution of reinforce-ment material. As a result, there would bemany micro and macro defects in thewelded joint (Refs. 3, 4). As there are anumber of problems that may occur in theprocess of fusion welding, the frictionwelding method (a solid form weldingprocess) proves to be more effective.

Friction welding is a method that doesnot cause melting in the welded zone, andit works through applying friction-inducedheat on the surfaces of materials. The fric-tion welding process is entirely mechani-cally powered, without any aid from elec-trical or other energy sources (Refs. 5, 6).In friction welding, the surfaces that cre-ate the friction during the welding processare maintained under axial pressure,known as the friction stage (Ref. 7). Whenthe appropriate temperature is reached,the rotation movement is stopped, and theupset pressure is applied. The weldingzone is thus subjected to a type of thermo-mechanical process that prevents grainstructure deterioration (Refs. 8, 9). Fric-tion welding is a method that can be usedin materials that have different thermaland mechanical properties.

Midling and Grong (1994) were con-

Continuous Drive Friction Welding ofAl/SiC Composite and AISI 1030

After examining the joining of a SiC particulate-reinforced A356 aluminum alloyand AISI 1030 steel, the outcome shows an aluminum matrix composite

and AISI 1030 steel can be joined by friction welding

BY S. ELIK AND D. GNE

KEYWORDS

Friction WeldingWeldability TestingMetal Matrix CompositeCarbon Steel

S. ELIK ([email protected]) and D.GNE are with Balikesir University, Faculty ofEngineering and Architecture, Dept. of Mechani-cal Eng., Cagis Campus, Balikesir, Turkey.

ABSTRACT

In conventional welding methods, such as those used in joining ceramic-reinforcedaluminum matrix composites, a variety of problems occur. For instance, the elementused for reinforcement, which increases the viscosity in the melting stage, makes themixing of matrix and reinforcement material difficult, and this causes inferior joiningquality and makes the establishment of welding difficult. Also, chemical reactions andundesirable phases are observed because there is a difference between the chemicalpotential of the matrix and reinforcement material. In this study, joining a SiC partic-ulate-reinforced A356 aluminum alloy and AISI 1030 steel by continuous drive frictionwelding was investigated. The integrity of the joints was also investigated by optical andscanning electron microscope (SEM), and the mechanical properties of the weldedjoints were assessed using microhardness and tensile tests. The results indicate that analuminum matrix composite and AISI 1030 steel can be joined by friction welding.

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cerned with the development of an overallprocess model for the microstructure andstrength evolution during continuous-drive friction welding of AI-Mg-Si alloysand AI-SiC metal matrix composites. InPart I, the different components of themodel are outlined and analytical solu-tions presented, which provide quantita-tive information about the heat-affectedzone (HAZ) temperature distribution fora wide range of operational conditions. InPart II, the heat and material flow modelspresented in Part I are utilized for the pre-diction of the HAZ subgrain structure andstrength evolution following welding andsubsequent natural aging. The models arevalidated by comparison with experimen-tal data and are illustrated by means ofnovel mechanism maps (Refs. 10, 11).

In their study, Pan et al. (1996) investi-gated the microstructure and mechanicalproperties of dissimilar friction joints be-tween aluminum-based MMC and AISI304 stainless steel base materials. The in-terlayer formed at the dissimilar joint in-terface was comprised of a mixture ofoxide (Fe(Al,Cr)2O4 or FeO(Al,Cr)2O3)and FeAl3 intermetallic phases. The notchtensile strength of dissimilar MMC/AISI304 stainless steel joints increased whenthe rotational speed increased from 500 to1000 rev/min, and at higher rotationspeeds there was no effect on notch tensile

strength properties (Ref. 12).Zhou et al. (1997) examined the opti-

mum joining parameters for the frictionjoining of aluminum-based, MMC materi-als. The notch tensile strengths ofMMC/Alloy 6061 joints are significantlylower than MMC/MMC and Alloy6061/Alloy 6061 joints for all joining pa-rameter settings. The fatigue strengths ofMMC/MMC joints and Alloy 6061/6061joints are also poorer than the as-receivedbase materials (Ref. 13).

Uenishi et al. (2000) investigated spiraldefect formation and the factors affecting

the mechanical properties of frictionwelded aluminum Alloy 6061 T6 and6061/AI203 composite base materials. Spi-ral defects are flow-induced defectsformed when material and reinforcing

Fig. 1 Tensile strength values of welded samples. Fig. 2 Hardness variations on horizontal distance.

Fig. 3 Macro picture of the sample with frictionwelding.

Fig. 4 Optical microstructures of weld zones withdifferent parameters (50). A Experiment 2; B experiment 3; C experiment 4; D experiment 5;E experiment 6.

A

C D

E

B


particles transfer to and are trapped in spi-ral arm regions located near the stationaryboundary of friction welded joints. Thetensile strengths of postweld heat treatedMMC/MMC joints produced using a fric-tion pressure of 280 MPa were signifi-cantly stronger than as-received MMCbase material (Ref. 14).

In their study, Lin et al. (2002) were ableto successfully conduct friction welding be-tween two composite materials with thesame matrix but a different reinforced ma-terial. Composite materials are SiC andAl2O3 reinforced A7005 aluminum alloy.For composite materials, the following wereused: size 6 and 15 m, SiC particulate vol-ume percentage of 10%, and 15 m Al2O3ceramic particulate of the same volume per-centage. Consequently, the use of a SiC par-ticulate led to a concentration of reinforce-ment particulate in the HAZ. This results inan increase in hardening values in the plas-tic region, weakening welding strength, andnarrowing HAZ (Ref. 15).

Lee et al. (2004) were able to achievefriction welding between a TiA1 alloy andAISI 4140 for a friction time of 3050 s,

upset pressure varying in a range of 300460MPa, and upset time of 5 s at a rotatingspeed of 2000 rev/min. On the AISI 4140side, they observed that the hardness valuesincreased to the range of 600900 HV, andno change in the TiA1 hardness value. How-ever, the tensile strength value was deter-mined to be as low as 120 MPa (Ref. 16).

Reddy et al. (2008) were able to success-fully weld AA6061 and AISI 304 austeniticstainless steel by means of the continuousrotating friction welding method. Directwelding of this combination resulted in brit-tle joints due to the formation of Fe2Al5. Toalleviate this problem, welding was carriedout by incorporating Cu, Ni, and Ag as a dif-fusion barrier interlayer. The interlayer wasincorporated by electroplating. Welds witha Cu and Ni interlayer were also brittle dueto the presence of CuAl2 and NiAl3. Agacted as an effective diffusion barrier for Feavoiding the formation of Fe2Al5. There-fore, welds with an Ag interlayer werestronger and ductile (Ref. 17).

In the study by Fauzi et al. (2010), the ex-amination of the interface withceramic/metal alloy friction welded compo-

nents is essential for understanding thequality of bonding between two dissimilarmaterials. Optical and electron microscopyas well as four-point bending strength andmicrohardness measurements were takento evaluate the quality of bonding aluminaand 6061 aluminum alloy joints produced byfriction welding (Ref. 18).

In this study, the joining capability ofSiCp-reinforced A356 aluminum matrixcomposite and AISI 1030 steel was stud-ied by continuous-drive friction welding.Therefore, after welding of samples, ten-sile and hardness experiments were car-ried out. For metallographic investiga-tions, optical microscope and SEM havebeen used. Energy-dispersive spec-troscopy (EDS) analysis was carried outfor chemical composition investigationson welding and HAZs.

Experimental Procedure

In this study, SiCp-reinforced A356aluminum matrix composite and AISI1030 steel were used. A SiC particulate-re-inforced A316 aluminum matrix compos-ite was prepared using the vortex method.In the Al/SiC composite material, somereactions take place between the matrixand reinforcement material during cast-ing. The Al4C3, which formed as a resultof these reactions, renders the weldingvery brittle. Very high heat input makesAl4C3 even more pronounced. The com-pound takes form at a temperature be-tween 700 and 1400C (Refs. 1, 19). Toprevent brittleness of the composite mate-rial caused by the Al4C3 compound, thevortex method that does not require veryhigh heat input is used. The casting wascarried out using the stir casting method at700C.

The chemical composition of the A356aluminum alloy is presented in Table 1. Itshould be noted that the SiC particulate

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Table 1 Chemical Composition of the A356 Material (wt-%)

Al Fe Si Ti Mn Zn Cu Mg Ni Cr92.28 0.12 7 0.2 0.03 0.02 0.02 0.28 0 0

Table 2 Chemical Composition of the AISI 1030 Steel (wt-%)

C Ni Cr Si Mn P Cu Mo Nb Fe0.297 0.100 0.082 0.143 0.636 0.011 0.167 0.011

volume percentage of 6% in 44 m di-mensions were used in the study. Lookingto the related literature (Ref. 20) and theresults of a number of preliminary cast-ings, it was assumed that 6% SiC would bethe appropriate particulate ratio to use.The chemical composition of AISI 1030steel is shown in Table 2. Mechanical prop-erties of this steel are presented in Table 3.The samples were processed at 20 80mm dimensions for friction welding.

The study was conducted using a con-tinuous-drive friction welding machine at3000 rev/min at the Engineering and Ar-chitecture Faculty of Balikesir University.Surfaces of the joining parts were ground,cleaned, and then fixed to the machine.The welding parameters, which were de-termined after consulting the relevant lit-erature (Refs. 15, 20, 21) and preliminaryexperiments, are shown in Table 4.

Tensile properties of the welded sam-ples were prepared according to the EN895 standard by leaving the welding zonein the center. When running tensile tests,4-mm/min tensile rates were used. Hard-ness tests were carried out in the cross-sec-

tion interface of the Al/SiC composite andAISI 1030 steel friction welded joints. Themicrohardness values were measured onboth sides of the welded specimens withthe Vickers method using a 50-g load.

The microstructural features of thefriction welded joints are investigated byusing optical and scanning electron micro-scopes. The samples were ground by usingSiC sandpapers and polished with a 0.3-m Al2O3 powder, then AISI 1030 andMMC sides were etched by using differentsolutions. The AISI 1030 was etched for 4s by using 4% nital, while the %6 Al/SiCp

material was etched for 2 min using aKeller reagent (2.5 mL HNO3, 1.5 mLHCI, 1 mL HF, and 95 mL distilled water).

Results and Discussion

Tensile Test Results

Friction welding experiments were con-ducted using the aforementioned weldingparameters. In the tensile test samples,fractures occurred on the side of the MMCmaterial in the HAZ. The occurrence offractures in the MMC zone was apparently


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Table 4 The Process Parameters Used in the Friction Welding Experiments

Experiment Friction Pressure Friction Time Upset Pressure Upset TimeNo. (Pf) (MPa) (tf) (s) (Pu) (MPa) (tu) (s)

Experiment 1 40 4 40 4Experiment 2 40 6 40 4Experiment 3 40 10 40 4Experiment 4 20 6 40 4Experiment 5 20 12 40 4Experiment 6 20 4 60 4Experiment 7 20 6 60 4Experiment 8 20 8 60 4

Fig. 6 The points where SEM images were taken. Fig. 7 SEM image of point A.

Fig. 8 SEM image of point B. Fig. 9 SEM image of point C.


caused by a deficiency of connection, whichis a reduced microjoining interface be-tween SiCp and A356 aluminum. On theother hand, the reason that a fracture tookplace in the welding zone could be attrib-uted to the presence of intermetallic phasessuch as Fe2Al5 and FeAl3, which resultedfrom the diffusion of materials. This wascaused by mechanical locking of the MMCand AISI 1030 materials, but it could alsobe the impact of SiCp, which prevented dif-fusion of the materials, the fact that Al andFe promote the intermetallic phases (Refs.12, 17, 22, 23).

The tensile test results of the friction-welded joints are given in Fig. 1 in a barchart format. According to the results ofthe tensile tests, the tensile strength of thesample from experiment 3 (99.05 MPa) is33.7% less than the tensile strength ofMMC (1349.57 MPa), while the tensilestrength of the sample used in experiment4 (53.99 MPa) is 63.9% less than the ten-sile strength of MMC. In general, the ten-sile strength of materials used in frictionwelding must be close to that of the mate-rial with the lowest tensile strength. In thetests, the tensile strength of the weldedzone was determined even lower than thatof MMC material, which has the loweststrength. This can be explained that thelack of strong interface connectionstrength between the reinforcement mate-rial and matrix material, and acting of SiCpas a gap in the welding zone reduces thewelding strength.

It can be concluded that the frictionwelding parameters are effective on jointstrength. With a long friction time, zones ofdiffusion containing brittle intermetalliccomponents were formed. A connectioncould not be established with a short periodof friction time and low friction rate withupset pressure. To obtain high strength, thefriction time must be as short as possible,while friction and upset pressure levels re-main high. In short periods of friction time,a very small diffusion area forms, and this

zone is removed from thejoining interface bymeans of pressure duringthe welding process inwhich upset pressure isexerted. The resultsmatched the data in pre-

viously conducted studies (Refs. 21, 23).

Microhardness Test Results

When looking at the hardness graph inFig. 2, it is clear that hardness values changewhen moving away from the welding zoneand toward the main materials. This changecontinues until the hardness values of themain materials are reached. On the MMCside, where particle fracture occurred, theincrease in hardness values begins as a moreparticulate concentrate in the unit area, andit reaches its maximum level on the steelside of the weld zone. Five of the test sam-ples with high tensile strength were exam-ined for microhardness, and the results areprovided in Fig. 2.

In experiments 2, 3, and 5, high pres-sure and a long period of friction led to anincrease in intermetallic phases with re-sulting deformation. This created an ex-pansion of the weld zone. It is observedthat deformation hardening, intermetallicphases originating from iron, aluminum,and fracturing of SiC increased the hard-ness in the region that deformed and nearto the weld zone (Ref. 24). It is possiblethat there were particle transitions in theviscose structure of these samples due tothe upset and heat. It should also be notedthat a part of Fe passes to the side of MMCduring welding, while Al and Si pass to theside of AISI 1030 and accumulate in theweld zone, causing an increase in hard-ness. These transitions were determinedby an EDS analysis, which is explained ina subsequent section. Due to the fact thatthe friction time of test samples was lessthan 10 s, the occurrence of higher hard-ness values, which could cause weakerwelding strength, was prevented.

In experiments 4 and 6, it was ob-served that the friction and upset pres-sures were low while the weld zone be-tween MMC and AISI 1030 materials wasnarrower than it ought to be. Because ofthis, diffusion between the materials

could not be achieved. This was due tothe fact that the friction pressure andtime were not sufficient for the materialsto diffuse, and the joint between the twomaterials was very slight. The highesthardness values of the weld zone weremeasured at the sample of experiment 3,while the sample from experiment 4showed the lowest microhardness values.It was observed that friction time andpressure values have a direct effect onmicrohardness values.

Macro- and Microstructure Results

The structural changes taking placewhen welding two different materials can beclassified into three different areas. Thefirst of these shows the partially deformedsection of MMC, while the second showsthe fully deformed section in the weld cen-ter, and the third shows the partially de-formed zone of AISI 1030 Fig. 3.

In examining the microstructure, it wasobserved that there were changes in theparticle structure of the MMC material,whereas not much change took place inthe AISI 1030 material. The reason nochange occurred on the AISI 1030 sidewas the low friction pressure and time.

In general, due to the effects of frictionand upset pressure, fracture in the SiC par-ticulate was observed in the MMC materialwhen approaching the weld zone. This phe-nomenon led to deposits of SiC in the weldzone. Uenishi et al. (Ref. 14) reported thatreinforcing Al2O3 particles in the MMCbase material are fractured in the zone closeto the weld interface. After samples wereexamined under an optical microscope, itbecame easier to explain why the hardnessvalues in the weld zone increased at higherpressure and time. Moreover, the occur-rence of Al-Fe intermetallic phases is ex-pected as a result of heat generated by thefriction as well as upset pressure. In the lit-erature (Refs. 12, 17, 22, 23), it has beenclaimed that intermetallic phases betweenAl and Fe such as Fe2Al5 and FeAl3 can takeplace after the diffusion of the materialsunder high pressure if a sufficient amountof heat (at higher than 400C) is provided.The subject materials intermetallic phasesadversely affect the weld strength becausethey form a brittle structure. To prevent this,

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Fig. 11 Linear EDS analysis results of the weld zone.

Fig. 10 EDS analysis line and points on experiment 3.


there must be high friction and upset pres-sure, as well as sufficient friction time men-tioned before.

Figure 4 depicts the microstructure im-ages of samples in five different experi-mental conditions. In examining samples 4and 6, it can be observed that the weldingis like a line, and the zone of transitionwhere the materials diffuse into eachother is not revealed. In visual and micro-scopic examinations of the samples, it wasobserved that flange and weld zones werenot formed. It was also observed that thematerials were connected only by meansof mechanical locking, and there was nodiffusion between the materials due to thefact that the necessary friction tempera-ture could not be achieved with the insuf-ficient friction pressure and time.

The joining quality of the samples fromexperiments 2, 3, and 5 was very good, es-pecially as the width of the weld zone caneasily be seen. It can further be seen fromMMC that the materials are sufficiently dif-fused to ensure joining. The diffusion be-tween the materials as well as the formationof the weld zone was adequately achieveddue to the high pressure and sufficient fric-tion. Detailed microstructural images be-long to the zones 1, 2, and 3 depicted in Fig.3 are shown respectively in Fig. 5AC.

In the friction welding process, circularvelocity is zero at the center. As the diam-eter and distance from the center in-creases, this velocity increases. In connec-tion with this, friction and temperaturerise. Moreover, the width of the HAZ getslarger (Refs. 2426). These changes wereinvestigated throughout the welded areaat various recorded distances from thewelding center. Deeply assessed points ofA, B, and C in the welded joint are de-picted in Fig. 6, and SEM images of thesepoints taken from the welded joint zoneare shown in Figs. 79. Following the SEMinvestigation, a linear EDS analysis ofzone C was carried out. In Fig. 10, the linesand points used in the EDS analysis are re-vealed, and Fig. 11 depicts the results. In

Table 5, values ob-tained from pointanalysis can be seen.

Examining the SEMimages and EDS re-sults, the distributionof Al, SiCp, and Fe can

be seen in the weld zone. In the weld zone,it can be observed that the Fe element ismore diffused on the side of the MMCwhile Al and SiCp were not very diffusedon the AISI 1030 side. On the side ofMMC, as the weld zone is approached, thesize of the SiC particulate became smaller;in other words, they were broken. As waspreviously explained, microhardness val-ues in the weld zone increase as theamount of particulate in each unit zone in-creases, which in itself is caused by thefracture of SiC particulate that accumu-lated in the weld zone. In the SEM images,SiCp clustering in the weld zone was notobserved. This supports the results thatthe weld strength in this sample is high.

When examining the fracture surfacesmore closely, we can see smooth andbright surfaces that mean it is a brittle frac-ture. In Fig. 12, it can be observed thatthere were many indentations on the sur-face in the form of white braids that re-sulted from the tensile force that was ap-plied. Also, there were large dents withductile fractures prevalent in these sec-tions of the material.

To be able to understand the Fe, SiCp,and Al status on the fracture surface, a lin-ear EDS analysis was taken on the AISI1030 Fig. 12. The results of the linearanalysis are shown in Fig. 13. The fact thatSiC, Al, and Fe materials are on the samesurface and also that there are remains ofMMC material on the fracture surface indi-

cate the fracture took place on the MMCside close to the welding zone.

Conclusions

1. In the tensile tests applied to thewelded samples, it was observed that exper-iment 3 had the highest tensile strength(99.05 MPa), whereas experiment 4 had thelowest tensile strength (53.99 MPa). It wasobserved that friction pressure and frictiontime were important for welding strength.Friction pressure has to be at the optimumvalue where it does not cause high defor-mation but still allows for diffusion.

2. In the examinations of hardness per-formed on the welded samples, hardnessvalues are not linear, also they increasewhile moving away from the welded zonetoward the main materials. The increase inhardness values in the welded zone is theresult of intermetallic phases such asFe2Al5 and FeAl3, internal stress generat-ing by high temperature differences, de-formation hardening, and fracturing ofSiCp because of high pressure in the zone.

3. In the microstructural examinationsperformed on the weld zone, three sepa-rate zones were encountered: the HAZside to the MMC; the weld zone (de-formed after being exposed to high tem-perature values); and the HAZ side toAISI 1030. Substantial structural changewas not observed in the HAZ side to AISI1030. This is due to the fact that the tem-perature did not reach sufficient values forthe deformation of AISI 1030 during fric-tion welding.

4. In investigating the SEM images, thediffusion of SiCp, Al, and Fe were ob-served in the weld zone. It was also notedthat as SiC was located closer to the weld


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Fig. 12 SEM image of fracture surface on the side of AISI 1030 materialand EDS analysis line.

Fig. 13 Linear EDS analysis results of fracture surface on the side of AISI1030 material.

Table 5 EDS Analysis Values Obtained from Points in Fig. 10

(1) (2) (3) (4) Element wt-% wt-% wt-% wt-%

C K 4.763O K 8.770 Al K 56.328 78.551 Si K 34.902 5.702 0.193Fe K 15.747 100.000 94.326


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zone, it fractured, and its size diminisheddue to the effect of upset pressure. This, inturn, caused an increase in plastic defor-mation and to rise in the hardness value.

5. According to the tensile and hard-ness tests and the microstructure, SEMand EDS investigations, the best weldingparameters were in experiment 3 (Pf = 40MPa, Pu = 40 MPa, tf = 10 s, tu = 4 s). Atlocations where MMC and AISI 1030 haveto be used together, the use of frictionwelding as a joining method resulted in therealization of the welding in a very shorttime by working below melting tempera-tures. More specifically, it has shown thatSiC-reinforced A356 aluminum alloy canbe successfully joined to AISI 1030 steel byfriction welding.

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26. elik, S., and Erszl, I. 2009. Investi-gation of the mechanical properties and mi-crostructure of friction welded joints betweenAISI 4140 and AISI 1050 steels. Materials andDesign 30: 9706.

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