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<p>Energy conservation and emission reduction is a crucial issue. Aluminum/steel composite structural components can save energy by utilizing the beneficial properties of dissimilar metals, meeting product requirements while reducing weight. Friction stir welding (FSW) is one of the most promising techniques for joining dissimilar materials. This paper focuses on 5083 aluminum alloy and Q235 steel. Using the coupled Euler-Lagrange method, a finite element model of butt FSW for these two materials under positively biased tool conditions is established. Then, considering the simulation results and actual welding equipment conditions, the one-factor test method is employed to design butt friction stir welding experiments for three welding parameters: offset, welding speed, and rotational speed. The mechanical properties, microstructure, and morphology of the joints produced with various weld parameters were also investigated experimentally. Numerical analysis indicates that the optimal welding parameters for 5083 aluminum alloy and Q235 steel are a welding speed of 55&#xa0;mm/min, a rotational speed of 400 r/min, and an offset of 0.7&#xa0;mm. Twelve groups of welding parameter combinations are designed based on existing conditions. Experiments show that all three parameters affect weld formation via heat input. Offset influences the distribution of steel fragments in the weld channel, while welding speed affects weld surface flatness.</p>

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5083 Aluminum Alloy/Q235 Steel Dissimilar Metal Stir Friction Welding Process Analysis

  • 期刊论文

  • 发表日期：

    2025年10月16日

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  • Wei Liu,
  • Chongyang Wang,
  • Hongshen Zhang

摘要

Energy conservation and emission reduction is a crucial issue. Aluminum/steel composite structural components can save energy by utilizing the beneficial properties of dissimilar metals, meeting product requirements while reducing weight. Friction stir welding (FSW) is one of the most promising techniques for joining dissimilar materials. This paper focuses on 5083 aluminum alloy and Q235 steel. Using the coupled Euler-Lagrange method, a finite element model of butt FSW for these two materials under positively biased tool conditions is established. Then, considering the simulation results and actual welding equipment conditions, the one-factor test method is employed to design butt friction stir welding experiments for three welding parameters: offset, welding speed, and rotational speed. The mechanical properties, microstructure, and morphology of the joints produced with various weld parameters were also investigated experimentally. Numerical analysis indicates that the optimal welding parameters for 5083 aluminum alloy and Q235 steel are a welding speed of 55 mm/min, a rotational speed of 400 r/min, and an offset of 0.7 mm. Twelve groups of welding parameter combinations are designed based on existing conditions. Experiments show that all three parameters affect weld formation via heat input. Offset influences the distribution of steel fragments in the weld channel, while welding speed affects weld surface flatness.