A study on residual stress generation versus recrystallisation in FSW joint of dissimilar alloy pair of the AA5083 and HSLA steel

Abstract

The distribution of residual stresses across the joint interface of dissimilar joining between AA5083 and HSLA steel by friction stir welding technique was investigated through 2D XRD method and a numerical simulation model. The measured and simulated residual stress distributions are compared and discussed in the context of active recrystallisation mechanism and the possible presence of intermetallic compound (IMC) layers across the joint interface. The active dynamic recrystallisation (DRX) and multiple Fe/Al series IMCs as evident from the EBSD and 2D XRD, respectively critically demonstrated the variation in residual stresses between the experimental and theoretical values. The highest residual stress values of 375 and 281 MPa were recorded for the HSLA steel side and AA5083 side, respectively.

KEYWORDS:

• FSW between the AA 5083 and HSLA steel
• residual stress distribution in FSW
• dynamic recrystallisation
• IMC layers
• FEM simulation of FSW

Acknowledgements

The authors acknowledge the National Facility of Texture and OIM – Supported by DST (IRPHA), Indian Institute of Technology Bombay, Powai, Mumbai – 400076, for conducting EBSD mapping and 2D XRD Lab, CRF, Indian Institute of Technology Kharagpur – 721302, for evaluating phases and residual stresses.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

The data that support the findings of this study are available from the corresponding author, Subhas Ganguly, upon reasonable request.