[

23

p. 352-3582005)]

Al-Mg 5052

**

***

****

***

Effect of Intermetallic Compound Layer on Bond Strength of Friction-welded Interface of

Al-Mg5052 Alloy to Mild Steel

by YAMAMOTO Naotsugu**, TAKAHASHI Makoto***, ARITOSHI Masatoshi**** and IKEUCHI Kenji***

The metallographic factor controlling the strength of friction-welded interface of Al-Mg alloy 5052 to mild steel S10C has been
investigated in nano-scale mainly by TEM observations. The bond strength, estimated from the tensile strength of a specimen with a
circumferential notch at the interface, increased rapidly with an increase in friction time and then reduced when the friction pressure was
20MPa. A maximum strength of 327 MPa was obtained at a friction time of 4 s (rotation speed = 20 s-1 and forge pressure = 230 MPa). At a
friction time of 1 s, the interface consisted of areas where an IMC(Intermetallic compound) layer about 30 nm wide was formed and areas
where no IMC layer could be detected. In addition, an Al oxide film of a width less than 10 nm was observed at the interface of the mild steel
substrate to the IMC layer and Al alloy substrate. With an increase in friction time, the volume of the IMC was increased and the Al oxide
film remained in narrower areas to be almost disappeared at the maximum bond strength. At friction times shorter than that to obtain the
maximum bond strength, fracture occurred mainly along the Al oxide film, suggesting that the bond strength was controlled by the Al oxide
film. At friction times longer than that to obtain the maximum bond strength, joint were fractured in the IMC layer, which occupied almost
whole areas of the interface. The bond strength of these joints decreased almost linearly with the increased in the width of the IMC layer
irrespective of the friction time and pressure. Thus the factor controlling the bond strength can be considered to alter from the Al oxide film to
the IMC layer with the increase in friction time. The IMC layer consisted mainly of Fe2Al5 and Fe4Al13. Small amount of FeAl2 was also
detected. These compounds were granular and distributed randomly in the IMC layer. The width of the IMC layer was increased almost in
proportion to the friction time at a rate which rose with friction pressure. These results suggest that the growth of the IMC layer is controlled
by mechanical mixing of Al and Fe at the interface as well as the diffusion.
Key Words: friction welding, dissimilar metal joint, aluminum magnesium alloy, mild steel, transmission electron microscope observation,
intermetallic compound, oxide layer

1.

* 16 12 6 16

** Student Member, Graduate

School of Engineering Osaka University
***
Member, Joining and
Welding Research Institute Osaka University
****
Member, Hyogo
Prefectural Institute of Technology

WallachElliott 3,4)
1
1m
Al

5-14)
1m
m
Al

1m

10

1m

15

 23 2005

353

Fig. 216)

3.3310-2 mm/s

TEMTEM

Al-Mg 5052

JEOL2010 160-200V

TEM FIBFocused Ion Beam

FIB

2.

S10C Al-Mg A5052Al

3.

Table 1 2
S10C Fig.1

Fig. 3

19mm 16mm 25mm

1.6 mRa

Fig. 4 20 MPa

Al

40 MPa

Table 3

1 s

Table 1 Chemical composition of the S10C

Table 2 Chemical composition of Al alloy

Fig. 1 Dimensions of the specimens used

Fig.3 Appearances of friction welded joints(a)P1=20 MPa, t1=1 s

(b) P1=20 MPa, t1=4 s (c) P1=20 MPa, t1=5 s (d) P1=40 MPa, t1=4 s.

Table 3 Bonding parameters

Fig. 2 Dimensions of test pieces for the tensile test

Fig. 4 Tensile strength of joint vs. friction time

354

Al-Mg 5052

Fig. 7 Interfacial layer observed in a joint bonded at a friction

time of 1s (P1=20 MPa)

Fig. 5 Fractured surface of

the A5052/S10C joint(t1=1):
(a) SE image of the S10C
side, (b) high magnification
of the area indicated by the
rectangle
in
(a),
(c)
distribution of Al, (d) image
the A5052side fractured
surface conjugate to area (b)
and (e) distribution of Fe.

Fig. 6 Fractured surface of

the A5052/S10C joint(t1=5):
(a) SE image of the S10C
side, (b) high magnification
of the area indicated by the
rectangle
in
(a),
(c)
distribution of Al, (d) image
the A5052side fractured
surface conjugate to area (b)
and (e) distribution of Fe.

Fig. 8 TEM micrograph and

SAD pattern of Fe2Al5

Fig. 9 EDX spectra from Al

oxide layer

20 MPa
t1=1 s
Fig. 5(a) SEM

Fig. 10 Interfacial layer observed in a joint bonded at a friction

time of 5s (P1=20 MPa)

Fig. 5(b)
Al Fig. 5(d)
EPMA
S10C Al(Fig. 5(c))
Al Fe(Fig. 5(e))
Al

Fig. 11 TEM micrograph

and SAD pattern of Fe2Al5

Fig. 12 TEM micrograph

and SAD pattern of FeAl2

Al
Fe
Al Al Fe

t1=5 s Fig.6
Fig.5 Fig. 6(c)
Fig. 6(e) AlAl
Fe
5s Al Fe

Fig. 13 TEM micrograph

and SAD pattern of Fe4Al13
Table 4 Chemical analyses at points, 1 to 6 indicated in Fig. 10 (at%)

40 MPa 1s
Fig.6

20 MPa 1s

Fig. 7

5 mm TEM

23 2005

355

Fig. 8
Fe2 Al5 Fe2Al5 10 nm

Al EDX Fig.
7 Fig. 9 Al
O Fe Al
16 12.5

Fig. 14 Interfacial layer observed in a joint bonded at a friction

time of 4s (P1=40 MPa)

Al Al
Al

t1=5 s Fig. 10

500 nm
Fig. 1112 13
Fe2Al5FeAl2 Fe4Al13
Fe2Al5 Fe4Al13
FeAl2
Fe Al

Fe

Fig. 15 TEM micrograph of a vertical section of a fractured

surface (P1=20 MPa, t1=1 s (a)A5052 side (b) S10C side)

Table 4
Fig. 10 16 Al/Fe EDX
3 6
3 Fe
Fe

Al Fe

40 MPa 20 MPa
Fe2 Al5 Fe4 Al13

Fig. 16 TEM micrograph

and SAD pattern of Fe2Al5

Fig. 17 EDX spectra from

Al oxide layer

Fig. 14 40 MPa
4 s Fig. 10

Fig.5, 6
Fig.7~13
Al

TEM
Fig. 15(a) 20 MPa
1 s Al
Al

Fig. 18 EDX spectrum from

joint interface

Fe2Al5 Fig. 16
Fig. 15(b)

Fig. 15(b)
EDX Fig. 17 Fe

356

Al-Mg 5052

Al O Mg
Al
Fig. 15(b)

EDX Fig. 18 O

Al
Al

Fig. 19 TEM micrograph of a vertical section of a fractured

surface (P1=20 MPa, t1=5 s (a)A5052 side (b) S10C side

Fig.19(a) 19(b) 20 MPa

5 s
Al

Fe2 Al5(Fig. 20) Fe4Al13(Fig. 21)

Fig. 20 TEM micrograph

and SAD pattern of Fe2Al5

40

Fig. 21 TEM micrograph

and SAD pattern of Fe4Al13

MPa 4 s Al
Fig. 22(a) 22(b) 20
MPa 5 s
Fe2 Al5 Fe4 Al13

Fig. 23
200 nm

Fig. 22 TEM micrograph of a vertical section of a fractured

surface (P1=40 MPa, t1=4 s (a)A5052 side (b) S10C side

Al
Al

18)

200 nm

220 nm Al

17
Al
O,Cr,Fe Ni 25 nm

19

20

1.52 m
Al
A5052 S25C
1m

 23 2005

357

10),19-21)

733 K 22

Fe Al

Fe-Al

t
21)
d2=Kt

K=K0exp(-Q/RT)

2
2

Fig. 23 Tensile strength of joint vs. IMC width

K0 (m /s)Q (J/mol)
R (J/molK-1)T (K)

20

Al

12 K0
Q Al-Mg 5052
K05.6810-2(m2/s)Q=176(kJ/mol)
12

Fig. 24
1

733 K 5 s
284 nm
Fig. 24 IMC width vs. friction time.
7)

40 MPa 20 MPa
13

1050 S15C

1m

7 MPa 28 MPa

20 K Fig. 24 40 MPa

1m 200 nm

4 s

1000 nm
1

810 K

Al

Al

Fe

2040 MPa 15 s

Fe2Al5Fe4Al13

Fe Al

FeAl2 Fe-Al

Al

FeAl Fe3 Al

Al Fe

358

Al-Mg 5052

Al-Fe

6)

Fe Al

7)

8)

4.

9)

Al-Mg 5052

10)

11)

40 MPa ,20 MPa

12)

Al

13)

2 40 MPa 20 MPa

14)

15)

3FeAl2 Fe2Al5
Fe4Al13 Fe2Al5

16)

Fe4Al13FeAl2
4

17)

18)

Fe Al

19)

1)

2)

3)
4)
5)

S. Imaizumi: Welding of Aluminium to Dissimilar

Metal()Summary and Fusion WeldingJournal of Light Metal &
construction221984pp. 310-320. (in Japanese)
S. ImaizumiWelding Aluminium to Dissimilar Metals()Solid
State BondingJournal of Light Metal & Construction221984

pp. 408-419. (in Japanese)

S.Elliott and E.R.Wallach: Joining aluminium to steel Part
1-Diffusion bonding, Metal Construction, (1981), pp.167-171.
S.Elliott and E.R.Wallach: Joining aluminium to steel Part
2-Friction bonding, Metal Construction, (1981), pp.221-225.
S. Fukumoto, T. Ono, H. Tsubakino, M.Aritoshi, T. Tomita and K.

20)

21)

22)

OkitaFormation Process of Reaction Layer between Aluminum

Alloys and Stainless Steel by Friction WeldingJournal of Light
Metal & construction40(2002), pp. 22-28. (in Japanese)
M.Yilmaz and M.Acet: Interface properties of aluminum/steel
friction-welded components, Materials Characterization, 49(2003),
pp.421-429.
A. Hasui, M. Ogawa and H. Tanaka: Friction Welding of
Aluminium and Carbon Steel, Journal of The Japan Welding
Society, 46(1977), pp.858-862. (in Japanese)
M. Kikuchi, H. Takeda and S. Morozumi: Bonding interfaces in
friction-and explosive-welded aluminum and steel joints, Journal
of Japan Institute of Light Metals, 34(1984), pp.165-173. (in
Japanese)
G. Kawai, K. Ogawa, H. Ochi and H. Tokisue: Friction weldability
of various aluminum alloy pipe to SUS304 stainless steel pipe,
Journal of Japan Institute of Light Metals, 49(1999), pp.83-88. (in
Japanese)
G. Kawai, K Ogawa, H.Ochi, and H. Tokisue: Friction Weldability
of Aluminum Alloys to Carbon steel, Journal of Light Metal &
Construction, 37(1999), pp.295-302. (in Japniese)
S. Fukumoto, H. Tsubakino, K. Okita, M. Aritoshi and T. Tomita:
Static joint strength of friction welded joint between aluminium
alloys and stainless steel, Welding International, 14(2000),
pp.89-93.
G. Kawai, K. Ogawa, H. Ochi and H. Tokisue: Friction weldability
of aluminium alloys to carbon steel, Welding International,
14(2000), pp.101-107.
T. Shinoda and S. Endo: Recent Development of Friction Welding
of Aluminium Alloys and Dissimilar Materials, Journal of Light
Metal & Construction, 33(1995), pp.321-327. (in Japanese)
T. Shinoda, M. Ogawa, S. Endo, and K. Miyahara: Friction
Welding of Aluminum and Plain Low Carbon Steel, Quarterly
Journal of The Japan Welding Society, 18(2000), pp.365-372. (in
Japanese)
S. Fukumoto, H. Tsubakino, K. Okita, M. Aritoshi, and T. Tomita:
Friction welding process of 5052 aluminium alloy to 304 stainless
steel, Materials Science and Technology, 15(1999), pp.1080-1086.
Y. Zhou, Z. Li, A. Fuji and T. H. North: Mecanical Properties of
Particulate MMC/AISI304 Friction Joints, ISIJ International,
35(1995), pp.1315-1321.
T. Kawano, M. Matsui, K. Nishio, M. Katou and M. Hirata:
Microstructural Observation on the Bond Interface in
A3003/SUS304L Clad Material, Quarterly Journal of The Japan
Welding Society, 22(2004), pp.291-299. (in Japanese)
H. Oikawa, T. Saitoh, T. Yoshimura and T. Nagase: Effect of Oxide
Film on Solid Phase Bonding of Aluminum Sheet to Steel Sheet,
TETSU-to-HAGANE, 83(1997), pp.629-634. (in Japanese)
S. Mukae, K. Nishio, M. Katoh, T. Inoue and K. Sumitomo: Effect
of Heat Treatment on Bond Characteristics of Aluminum Clad
Steel, Quarterly Journal of The Japan Welding Society, 12(1994),
pp.528-533. (in Japanese)
H. Oikawa, T. Saitou, T. Nagase and T. Kiriyama: Formation and
Growth of Intermmetallic Compound at Interface of
Steel/Aluminum Bonding Sheet, TETSU-to-HAGANE, 83(1997),
pp.641-646. (in Japanese)
K. Shibata, S. Morozumi and S. Koda: Formation of the Alloy
Layer in the Fe-Al Diffusion Couple, Journal of The Japan Institute
of Metals, 30(1966), pp.382-388. (in Japanese)
N. Yamamoto: Effects of Alloying Elements on the Strength of
Friction-bonded Interfaces of AL Alloys to Steel , Master Thesis of
Osaka University, 2002.(in Japanese)