A Novel Approach of Friction Stir Cladding of Aluminum on Carbon Steel Plate; Experimental Investigation and Material Characterization

Cladding is usually used to improve the material functionality (i.e. corrosion, wear, and oxidation) and to improve the mechanical and thermal properties of the components in different industries. In this study, a new cladding approach based on the friction stir processing was successfully employed on carbon steel plate with 6061-T6 Aluminum alloy. The mechanical and metallurgical properties of the cladding layer were examined at different process parameters. Metallurgical investigation of ST/Al interface was also evaluated using the Scanning electron microscope (SEM) and Optical microscope (OM). Two alloys were mixed uniformly together in the proper process conditions. Based on the results, the decrease of rotational speed from 1200 rpm to 800 rpm at a constant traverse speed of 15 mm/min, the cladding strength increased from 3.7 KN to 4.8 KN. At constant rotational speed of 800 rpm, with an increase in traverse speed from 15 mm/min to 35 mm/min, the cladding strength increased from 4.8 KN to 6.6 KN.