Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool
Abstract Friction-assisted plastic deformation at the joint interface is essential for achieving the desired joint properties in dissimilar friction stir lap welding (FSLW) of aluminum alloy (Al) with steel (Fe). This plastic deformation can be precisely controlled by using an adjustable tool, where...
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| Language: | English |
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Nature Portfolio
2025-07-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-12738-5 |
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| author | Amlan Kar Yoshiaki Morisada Abhishek Sharma Hidetoshi Fujii |
| author_facet | Amlan Kar Yoshiaki Morisada Abhishek Sharma Hidetoshi Fujii |
| author_sort | Amlan Kar |
| collection | DOAJ |
| description | Abstract Friction-assisted plastic deformation at the joint interface is essential for achieving the desired joint properties in dissimilar friction stir lap welding (FSLW) of aluminum alloy (Al) with steel (Fe). This plastic deformation can be precisely controlled by using an adjustable tool, where shoulder and probe rotation speeds are independently controlled. This study explores the effect of microstructure evolution and probe rotation speed on the weld’s interface morphology and tensile properties of FSLW joints between an aluminum alloy and steel using an adjustable tool. Microstructure evolution is influenced by inherent material properties and process-induced stress inhomogeneity. Grain refinement in Fe is more gradual compared to Al, which exhibits a homogenous microstructure. Lower probe rotation speeds lead to more significant grain refinement in Al, while increasing probe rotation speeds promote the formation of intermetallic compounds. An intercalated structure with varying fractions and morphology is observed across the joint interface in all welds. The controlled evolution of microstructure and the differences in intercalated structure formation at the weld interface are attributed to variations in shear strength. This study demonstrates the ability of an adjustable tool to tailor the microstructure and tensile properties of FSLW joints, providing a promising approach for enhancing joint performance in dissimilar metal joining applications. |
| format | Article |
| id | doaj-art-e76c7b0bdf3a40b59ea99dda8139305c |
| institution | Kabale University |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-e76c7b0bdf3a40b59ea99dda8139305c2025-08-20T03:45:56ZengNature PortfolioScientific Reports2045-23222025-07-0115111710.1038/s41598-025-12738-5Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable toolAmlan Kar0Yoshiaki Morisada1Abhishek Sharma2Hidetoshi Fujii3Arbegast Materials Processing and Joining Laboratory (AMP), South Dakota School of Mines & TechnologyJoining & Welding Research Institute, The University of OsakaJoining & Welding Research Institute, The University of OsakaJoining & Welding Research Institute, The University of OsakaAbstract Friction-assisted plastic deformation at the joint interface is essential for achieving the desired joint properties in dissimilar friction stir lap welding (FSLW) of aluminum alloy (Al) with steel (Fe). This plastic deformation can be precisely controlled by using an adjustable tool, where shoulder and probe rotation speeds are independently controlled. This study explores the effect of microstructure evolution and probe rotation speed on the weld’s interface morphology and tensile properties of FSLW joints between an aluminum alloy and steel using an adjustable tool. Microstructure evolution is influenced by inherent material properties and process-induced stress inhomogeneity. Grain refinement in Fe is more gradual compared to Al, which exhibits a homogenous microstructure. Lower probe rotation speeds lead to more significant grain refinement in Al, while increasing probe rotation speeds promote the formation of intermetallic compounds. An intercalated structure with varying fractions and morphology is observed across the joint interface in all welds. The controlled evolution of microstructure and the differences in intercalated structure formation at the weld interface are attributed to variations in shear strength. This study demonstrates the ability of an adjustable tool to tailor the microstructure and tensile properties of FSLW joints, providing a promising approach for enhancing joint performance in dissimilar metal joining applications.https://doi.org/10.1038/s41598-025-12738-5Dissimilar friction stir lap weldingAdjustable tooProbe rotation speedMicrostructure evolutionWeld interface morphologyShear strength |
| spellingShingle | Amlan Kar Yoshiaki Morisada Abhishek Sharma Hidetoshi Fujii Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool Scientific Reports Dissimilar friction stir lap welding Adjustable too Probe rotation speed Microstructure evolution Weld interface morphology Shear strength |
| title | Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool |
| title_full | Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool |
| title_fullStr | Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool |
| title_full_unstemmed | Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool |
| title_short | Precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool |
| title_sort | precision control of microstructure variation and tensile properties in dissimilar friction stir lap welding joints using an adjustable tool |
| topic | Dissimilar friction stir lap welding Adjustable too Probe rotation speed Microstructure evolution Weld interface morphology Shear strength |
| url | https://doi.org/10.1038/s41598-025-12738-5 |
| work_keys_str_mv | AT amlankar precisioncontrolofmicrostructurevariationandtensilepropertiesindissimilarfrictionstirlapweldingjointsusinganadjustabletool AT yoshiakimorisada precisioncontrolofmicrostructurevariationandtensilepropertiesindissimilarfrictionstirlapweldingjointsusinganadjustabletool AT abhisheksharma precisioncontrolofmicrostructurevariationandtensilepropertiesindissimilarfrictionstirlapweldingjointsusinganadjustabletool AT hidetoshifujii precisioncontrolofmicrostructurevariationandtensilepropertiesindissimilarfrictionstirlapweldingjointsusinganadjustabletool |