  Optimization of the intermetallic layer thickness and the suppression of
interfacial defects are key elements to improve the load bearing capacity of
dissimilar joints. However, till date we do not have a systematic tool to
investigate the dissimilar joints and the intermetallic properties produced by
a welding condition. Friction Melt Bonding (FMB) is a recently developed
technique for joining dissimilar metals that also does not exempt to these
challenges. The FMB of DP980 and Al6061-T6 is investigated using a new physical
simulation tool, based on Gleeble thermo-mechanical simulator, to understand
the effect of individual parameter on the intermetallic formation. The proposed
method demonstrates its capability in reproducing the intermetallic
characteristics, including the thickness of intermetallic bonding layer, the
morphology and texture of its constituents (Fe2Al5 and Fe4Al13), as well as
their nanohardness and reduced modulus. The advantages of physical simulation
tool can enable novel developing routes for the development of dissimilar metal
joining processes and facilitate to reach the requiring load bearing capacity
of the joints.

Applied Physics;Materials Science