Microstructure and mechanical properties of friction stir lap welded dissimilar zirconium-steel joint

Abstract Friction stir lap welding (FSLW) was employed to weld dissimilar joints of zirconium and stainless steel for the first time. The microstructure, evolution mechanism of intermetallic compounds (IMCs) and mechanical properties of joint were investigated. Discontinuous dynamic recrystallization (DDRX) and continuous dynamic recrystallization (CDRX) occurred in zirconium, while DDRX occurred in stainless steel during FSLW. The formation sequence of IMCs at the interface was FeZr3, FeZr2, Fe2Zr, and Fe23Zr6. The crack nucleated at the hook zone on the advancing side (HookAS), and IMCs in the Zr/SS mixed zone accelerated crack propagation. The fracture surface exhibited ductile-brittle mixed fracture characteristic.