Experimental and numerical investigations into friction crush welding of aluminum and magnesium sheet metals for lightweight vehicle applications

Abstract

In recent years, the process of joining different materials has received much attention. This article investigates friction crush welding (FCW) of aluminum and magnesium sheet metals through numerical modeling and experimentation. A three-dimensional, explicit nonlinear finite element (FE) model was developed in ABAQUS utilizing the Lagrange technique. The influence of welding parameter impact like rotational speed (2700, 3500, and 5400 r/min) and welding speed (40, 50, and 60 mm/min) is also examined. The FE model was validated using experimental data from infrared thermography. The observed and predicted values of the weld's temperature are in excellent agreement. Field emission scanning electron microscopy was utilized to evaluate the microstructure of welded joints. Intermetallic compounds were identified using X-ray diffraction, and intermetallic phases such as Mg₂Al₃ and Mg₁₇Al₁₂ were found_. Chemical composition is determined by the use of energy dispersive spectroscopy. The optimal welding parameters for the aluminum–magnesium FCW joint and the impact of IC distribution on the mixing of materials in the weld zone were also determined. Results show that the optimal welding condition was obtained when welding was performed at 50 mm/min and a tool rotational speed of 5400 r/min.