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Potentials of Heat Superimposed Rotary Friction Welding for Steel-Aluminium Joints

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Abstract:

Hybrid joints made of steel and aluminium alloy produced by rotary friction welding, enable load-adapted lightweight components. However, a major challenge is the inhomogeneous radial temperature distribution caused by different relative velocities between the specimen centre and edge during rotation. This effect leads to local insufficient bonding and reduces the overall joint strength, especially in the centre, where low relative rotation speeds occur. Previous studies mainly addressed preheating before the friction phase, whereas superimposed heating during the upsetting phase has not been investigated so far. To achieve temperature equalisation along the cross-section during rotary friction welding, a modified KUKA Genius plus machine equipped with joule heating was used to introduce an electric current during the upsetting phase. Experiments were conducted on EN AW-6082 (AA-6082) joined to 20MnCr5 (AISI 5120H). A three-step variation of current intensity (10, 24 and 36 A/mm2), alongside a reference without current, was investigated. Temperatures were monitored using type K thermocouples, confirming temperature equalisation. Mechanical performance was assessed by uniaxial tensile tests, while hardness measurements and metallographic analyses characterised the influence of superimposed heating on the interfacial microstructure. Joint strength improves up to 20% with increasing current, linked to a uniform temperature distribution and enhanced material flow, resulting in a defect-free specimen centre.

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Periodical:

Materials Science Forum (Volume 1185)

Pages:

77-87

DOI:

https://doi.org/10.4028/p-hOTSU9

Citation:

Cite this paper

Online since:

April 2026

Authors:

Armin Piwek*, Julius Peddinghaus, Johanna Uhe, Kai Brunotte, Bernd Arno Behrens

Keywords:

Heat Superimposition, Hybrid Materials, Joining, Lightweight

Funder:

The publication of this article was funded by the Leibniz Universität Hannover (LUH) / Technische Informationsbibliothek (TIB)

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* - Corresponding Author

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