Optimization of friction stir welding process for joining of aluminum to steel

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Friction stir welding (FSW) is a solid-state welding process, which can produce high quality welds of several materials difficult to weld. Due to the low energy input used, FSW creates high strength joints with reduced distortion. Being capable of handling variations inherent to high volume production, advantages of FSW also include improved process robustness and reduced production costs. FSW has rapidly gained acceptance for the manufacturing of lightweight structures. The rising demands for improved fuel economy have driven the efforts for the development of innovative aluminum products for transportation vehicles. However, the majority of the structures used in vehicle involve steel and the employment of lightweight materials in steel structures is of great interest. The use of the combination of steel and aluminum alloys has been increasing in fabrication and many efforts to weld steel to aluminum alloy have been invested.