A Review on Welding of Dissimilar Metals in Car Body Manufacturing

Karim, Md. Abdul; Park, Yeong-Do

doi:10.5781/jwj.2020.38.1.1

Cited by 48 publications

(10 citation statements)

References 99 publications

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“…Therefore, if Al-Mg dissimilar alloy joints can replace some traditional steel parts, the weight will be significantly reduced [4]. Furthermore, these lighter materials are expected to significantly improve fuel economy through a reduction in vehicle mass [5]. Usually, traditional welding joints, such as fusion welding between magnesium and aluminum, tend to be problematic because of the issues of bonding welds with different high-temperature flow characterizations, as well as their overall heterogeneity [3,6], which can result in defects, voids, and brittle intermetallic compounds at the interfaces between the two alloys [7].…”

Section: Introductionmentioning

confidence: 99%

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Ding

Das

Upadhyay

et al. 2023

CMD

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Friction stir welded (FSW) aluminum–magnesium lightweight vehicle joints have gained significant interest due to their high strength-to-weight ratio. In this work, the corrosion resistance of this material is analyzed through electrochemical tests, which include open circuit potential (OCP) inspection and potentiodynamic polarization (PD) scanning. Weight loss measurements tested the corrosion rate of the FSW weld through cyclic corrosion testing (CCT) according to the standard SAEJ 2334. Mechanical properties were also investigated, including lap-shear strength, micro- and nano-hardness mapping, and true stress–strain curves as a function of local processing history. The electrochemical results indicate that the center weld zone’s corrosion property stays between the two base alloys. Indentation-based testing demonstrated that the weld zone behaves differently from base alloys. Lap shear strength surprisingly did not drop much even after eight weeks of cyclic corrosion tests, indicating that the joint did not allow any ingress of the electrolyte.

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Section: Introductionmentioning

confidence: 99%

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Ding

Das

Upadhyay

et al. 2023

CMD

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“…Brittle intermetallic compound formation was found to be sensitive in nonferrous dissimilar gas metal arc welding [1]. Excessive heat-affected zones were also produced by fusion welding techniques such as electric arc welding [2]. Another significant issue in this process is the formation of residual stresses due to compositional differences in joining metals [3].…”

Section: Introductionmentioning

confidence: 99%

Tensile Strength and Microstructure of Rotary Friction-Welded Carbon Steel and Stainless Steel Joints

Firmanto

Candra

Hadiyat

et al. 2022

JMMP

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Due to the different properties of the materials, the fusion welding of dissimilar metals may be difficult. Structural irregularities may form as a result of various phase transformations during welding. Solid-state welding, as opposed to fusion welding, occurs below the melting temperature. As a result of the melting and solidification phenomena that happen in fusion welding, solid-state welding is expected to reduce the potential for phase transformation. This paper describes the use of a rotary friction welding technique to join carbon steel and 304 stainless steel. The purpose of this work is to investigate the characteristics of rotary friction welding (RFW) when joining 304 stainless steel to carbon steels with different carbon contents. Experiments were carried out on the RFW of low- and medium-carbon steels with 304 stainless steel. The investigation was carried out using the Taguchi method of experimental design. The joints’ tensile strengths and microstructures were evaluated. The parameters that had the greatest influence on the tensile strengths of the welding results were identified. The combination of parameters resulting in the greatest tensile strength is also suggested. A microstructural examination of the weldment revealed mechanical mixing and interlocking.

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“…Underlying a solution to this problem is the process of surfacing steel welding wire on a titanium substrate. It is known, for example, from work [3], that, in this case, undesirable intermetallic phases (IMPs) could form, leading to the destruction of compounds. There are various procedures to eliminate the risk of such phases but all of them, to some extent, are based on reducing the thermal effect of the surfaced steel layer on the titanium layer.…”

Section: Introductionmentioning

confidence: 99%

Comparing features in metallurgical interaction when applying different techniques of arc and plasma surfacing of steel wire on titanium

Korzhyk

Khaskin²,

Grynyuk³

et al. 2021

EEJET

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This paper reports a study into the regularities of interphase interaction, features in the formation of intermetallic phases (IMPs), and defects when surfacing steel on titanium in four ways: P-MAG, CMT, plasma surfacing by an indirect arc with conductive wire, and PAW. A general tendency has been established in the IMP occurrence when surfacing steel on titanium by all the considered methods. It was determined that the plasma surfacing technique involving an indirect arc with conductive wire is less critical as regards the IMP formation. That makes it possible to obtain an intermetallic layer of the minimum thickness (25...54 μm) in combination with the best quality in the formation of surfaced metal beads. Further minimization of the size of this layer is complicated by a critical decrease in the heat input into the metal, which gives rise to the capability of the surfaced metal to be collected in separate droplets. The formation of TiFe2, TiFe, and the α-Fe phase enriched with titanium in different percentage compositions has been observed in the transition zone of steel surfacing on titanium under different techniques and modes of surfacing. The study has shown the possibility of formation, in addition to the phases of TiFe2 and TiFe, the Ti2Fe phase at low heat input. The technique of plasma surfacing by an indirect arc with conductive wire minimizes the thermal effect on the base metal. When it is used at the border of the transition of the layer of steel surfaced on titanium, the phase composition and structure of the layers in some cases approach the composition and structure of the transition zone of the original bimetallic sheet "titanium-steel" manufactured by rolling. A layer up to 5 μm thick is formed from the β phase with an iron concentration of 44.65 % by weight and an intermetallic layer up to 0.2...0.4 μm thick, close in composition to the TiFe phase. The next step in minimizing the IMP formation might involve the introduction of a barrier layer between titanium and steel.

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A Review on Welding of Dissimilar Metals in Car Body Manufacturing

Cited by 48 publications

References 99 publications

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Tensile Strength and Microstructure of Rotary Friction-Welded Carbon Steel and Stainless Steel Joints

Comparing features in metallurgical interaction when applying different techniques of arc and plasma surfacing of steel wire on titanium

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