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Hybrid joining of ultra high strength steel to aluminium with Friction Stir Welding

Reference number
Coordinator Swerea KIMAB AB
Funding from Vinnova SEK 500 000
Project duration October 2012 - December 2013
Status Completed
Venture FFI - Sustainable Production
End-of-project report 2012-02479sv.pdf(pdf, 557 kB) (In Swedish)

Important results from the project

The combination of ultra high strength steels (UHSS) and aluminium is expected to play a large role in the vehicles of the future. Today´s joining technology is associated with large difficulties when aluminium is joined to the UHSS of tomorrow. In the project we test the hypothesis that friction stir welding can be used to create high performance overlap joints between aluminium and UHSS. Trials on one AA5000 alloy and a DP800 steel show very good results with robust mechanical properties.

Expected long term effects

The project proposes an innovative joining method for tomorrows combination of aluminium and ultra high strength steels. This is well in line with the road map targets of the FFI programme regarding robustness, productivity, flexibility and cost efficiency.

Approach and implementation

In this application the friction stir tool penetrates the aluminium part and rubs towards the steel part. In this way high wear rates inside steel can be avoided. Trials on a AA5000 and a DP800 ultra high strength steel show good and reproducible mechanical properties of the overlap joint. The joint is created by a controlled chemical reaction in the interface layer between the steel and the aluminum.

The project description has been provided by the project members themselves and the text has not been looked at by our editors.

Last updated 25 November 2019

Reference number 2012-02479

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