Friction welding of 6061 aluminum alloy and S45C carbon steel using insert metal

Friction welding of a 6061 aluminum alloy to a S45C carbon steel was carried out using the insert metal of a 1050 aluminum. Optimum thickness of the insert metal, friction pressure, forge pressure, friction time and rotational speed of welding conditions were determined as 4 mm, 90 MPa, 300 MPa, 1.2 s and 2250 rpm, respectively. When the insert metal turned into a thin (20 to approximately 30 μm) and homogeneous layer at the weld interface, the maximum joint efficiency of tensile strength was obtained and was about 95%. Successful welds were obtained by taking each optimum welding condition even if the thickness of the insert metal was varied from 2 to 6 mm.