Impact of Various Rotary Friction Welding Process Parameters on the Mechanical Properties of a Steel–Aluminum Joint

Huber LK, Schultheiß P, Thiele M, Rößler C, Höppel HW (2025)

Publication Type: Journal article

Publication year: 2025

Journal

Advanced Engineering Materials Wiley

DOI: 10.1002/adem.202500842

Abstract

Lightweight materials offer a great potential for reducing CO2 emissions by enhancing energy efficiency. However, not all components can easily be replaced by lighter alternatives, but hybrid materials made from steels and aluminum alloys offer a viable solution to using lightweight materials on the one hand and withstanding high mechanical stresses on the other. Rotary friction welding is a promising method for fabricating such hybrids, as it enables joining without achieving the components’ melting points. The latter is particularly crucial for steel–aluminum joints due to their very different mechanical and physical properties where brittle intermetallic phases (IMP) are formed. A minimal thickness of IMPs is essential for achieving a high strength of the joints between steel E355 and EN AW-6082, but by exceeding a phase width of 0.4 μm the mechanical properties drop. Alloying elements, such as silicon and manganese, also impact the mechanical behavior of the joint. Silicon diffuses rapidly and has limited solubility in iron-aluminides IMPs, creating the hexagonal α-phase. In contrast, manganese diffuses slower and transforms hexagonal to cubic IMPs. Best result of Rm= 248 MPa with a joint quality of 65% is achieved at higher rotational speeds with low welding times.

Authors with CRIS profile

Laura-Kristin Huber Lehrstuhl für Werkstoffwissenschaften (Allgemeine Werkstoffeigenschaften) Phillipp Schultheiß Lehrstuhl für Werkstoffwissenschaften (Allgemeine Werkstoffeigenschaften) Heinz Werner Höppel Lehrstuhl für Werkstoffwissenschaften (Allgemeine Werkstoffeigenschaften)

Involved external institutions

LimFox GmbH DE Germany (DE) Sampro GmbH DE Germany (DE)

How to cite

APA:

Huber, L.-K., Schultheiß, P., Thiele, M., Rößler, C., & Höppel, H.W. (2025). Impact of Various Rotary Friction Welding Process Parameters on the Mechanical Properties of a Steel–Aluminum Joint. Advanced Engineering Materials. https://doi.org/10.1002/adem.202500842

MLA:

Huber, Laura-Kristin, et al. "Impact of Various Rotary Friction Welding Process Parameters on the Mechanical Properties of a Steel–Aluminum Joint." Advanced Engineering Materials (2025).

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