Influence of pin length on interfacial characteristics and tensile properties of friction-stir-butt-welded AA1060/Q235 clad plates

This study explores friction stir butt welding of AA1060/Q235 clad plates to address the chemical industry’s need for robust aluminum/steel clad joints. To manage the formation of intermetallic compounds, we employed FSW tools with varying pin lengths, enabling simultaneous welding of the interfacial transition zone and the cladding fusion zone. The pin length significantly influenced joint tensile strength by affecting three key factors: the thickness of the IMC layer, the effective thickness of the steel region, and interfacial microcracking. Optimal tensile strength was achieved when the pin length was adjusted so that its tip precisely reached the Al/steel interface. Although the study is constrained by the number of process parameters, the observed trends illuminate the initial correlations between processing conditions, interfacial characteristics, and mechanical performance. This underscores the necessity of balancing IMC growth with interfacial integrity.