Different intermetallic phases are forming in the contact area of steel to brazed seam in laser joined aluminium-steel mixed materials. The intermetallic phases are composed of elements from filler material, molten aluminium sheet and brazed steel sheet. They develop from the liquid stage of iron and aluminium or mainly from diffusion processes at the interface of brazed seam to steel sheet. These FeAl-phases are investigated by means of SEM, focused ion-beam (FIB) and TEM. The chemical compositions of the different FeAl-phases are determined with EDS and the crystal structure by selected area diffraction patterns. The morphology of the FeAl-phases change from a planar to a needle shape structure in direction from steel sheet to brazed seam. Since their high hardness and brittleness can have a strong effect on the mechanical behaviour and reliability of aluminium-steel mixed material joints the microhardness of the intermetallic phases was determined as well.
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