Dissimilar FSW of immiscible materials: Steel/magnesium

The dissimilar joint between a light metal and a strong metal such as steel, is necessary for reducing the weight of vehicles. Friction Stir Welding (FSW) is a useful process to obtain several kinds of dissimilar joints and many studies have already been reported. However, the joint between steel and magnesium has not been aggressively studied, because it is an immiscible system. Aluminum is one of the most popular alloying elements for magnesium, and the iron–aluminum system has many intermetallic compounds due to their strong interactions. In this study, the Fe–Al intermetallic compound layer was successfully formed at the joint interface between iron and magnesium using aluminum in the magnesium alloys. The joint strength increased with the increasing aluminum content of the magnesium alloy due to the depletion of aluminum at the magnesium side near the interface.