A Review and Case Study on Mechanical Properties and Microstructure Evolution in Magnesium-Steel Friction Stir Welding

Weight minimization and global environmental policies on carbon content open a new research avenue towards materials and manufacturing processes in transport industries. Friction stir welding (FSW) process is a combination of frictional heating and stirring action where materials are joined in their solid state. In this study, a review has been made on the joining status of magnesium alloys to steel by using FSW. Present problems and future opportunities of magnesium to steel joining with the help of FSW are also stated. A case study has also been presented where the joint characteristics of AZ31B to AISI 304 sheets fabricated in lap configuration by FSW have been investigated by varying tool rotational speed (600, 1000, and 1800 rpm) and varying weld speed (40, 200, and 350 mm/min). A maximum weld joint efficiency of 79% of the AZ31B base alloy has been achieved with a parametric combination of 600 rpm and 350 mm/min.