Dissimilar metal joining of aluminum to steel by ultrasonic plus resistance spot welding - Microstructure and mechanical properties

Lu, Yu; Mayton, Ellis; Song, Hyeyun; Kimchi, Menachem; Zhang, Wei

doi:10.1016/j.matdes.2019.107585

Cited by 54 publications

(19 citation statements)

References 31 publications

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“…Many kinds of materials will inevitably be customized with different shapes, connected with themselves or other materials during application. As an efficient and stable connection mode, different welding methods have been proposed and applied to the joint of Mo-Re sheet or wire, such as resistance welding [7], [8], [9], electron beam welding, laser beam…”

Section: Introductionmentioning

confidence: 99%

Micro Resistance Spot Welding Optimization for Ultra-Thin Mo-Re Sheet Used in TWT

Wang

Fen

2023

IEEE Access

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30 µm ultra-thin Mo-Re sheet had been joined by micro resistance spot welding (MRSW) and successfully applied to the low heating power cathode of traveling wave tube (TWT). The effects of different welding parameters, surface state and protection conditions on the joint's appearance, micro-structure and lap shear strength (LSS) were analyzed in this paper. The results showed that a 63.5 N LSS of the MRSW joint was obtained under the following conditions: electrode force F = 9.0 N, welding current I = 1000A, ramping time t 1 = 5ms, welding time t 2 = 2ms and dip in the alcohol for protection. The fracture occurs in the heat affected zone (HAZ). Using metallurgical microscopy observed the nugget, metallurgical fusion could be found, the diameter of nugget was about 0.3 mm, without gas pores. Scanning electron microscopy (SEM) was used to observe the fracture surface. It could be found some ''whisker'' shape diverged from the joint center to the surroundings in HAZ. The electrode tip was observed by energy dispersive spectroscopy (EDS) and optical profiler. It was found that the tip was uneven and adhered the base metal obviously after spark. Additional work about electrode sticking will be required. The thermal test data showed that the use of ultra-thin Mo-Re sheet can reduce a space TWT cathode heating power (CHP) by 0.57 W, which will effectively save satellite energy and improve the expected working life of vacuum electronic devices.INDEX TERMS Ultra-thin Mo-Re sheet, micro resistance spot welding (MRSW), welding parameters optimization, lap shear strength (LSS), cathode heating power (CHP), traveling wave tube (TWT).

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Section: Introductionmentioning

confidence: 99%

Micro Resistance Spot Welding Optimization for Ultra-Thin Mo-Re Sheet Used in TWT

Wang

Fen

2023

IEEE Access

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“…They have been widely used in the fields of automobile manufacturing, metallurgy, and aerospace [7]. Due to the differences in their physical and chemical properties, the formation of brittle Fe-Al intermetallic compounds (IMCs) and weld properties appear at the interface and Al side [8][9][10]. Furthermore, different welding methods, including single fusion welding, laser-arc welding, friction stir welding, etc.…”

Section: Introductionmentioning

confidence: 99%

Plasma-Pulsed GMAW Hybrid Welding Process of 6061 Aluminum and Zinc-Coated Steel

Zhang

Zheng³

et al. 2023

Crystals

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A novel plasma-pulsed GMAW hybrid welding (plasma-GMAW-P) process is proposed for joining 6061 aluminum and zinc-coated steel. The results show that the change in welding heat input has little effect on the microstructure of the joint and the composition of the intermetallic compounds (IMCs) but only changes the thickness of the reaction layer (increased from 5 μm to 12 μm). when the plasma arc current is 20 A and the MIG current is 80 A, the welded joint obtained has the highest tensile-shear force. With the optimal process parameters, the weld strength obtained by filling ER4043 welding wire is the highest, accounting for 65% of the tensile-shear force of the base material. The effect of the plasma arc acting on the joint properties is studied through the microstructure and a tensile-shearing test. The action position of the plasma arc plays a significant role in the Al/steel interface, which directly influences the strength of the welded joints. Regardless of the plasma-GMAW-P style used to obtain the joints, Fe-Al IMCs appear at the interface. When the plasma arc is in front of the welding direction and the GMAW-P arc is in the rear, the tensile-shear force reaches the maximum of 3322 N.

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“…Welding of aluminum alloys with the steel structures has been carried out using various welding techniques, such as cold metal transfer [5], surface activated bonding [6], ultrasonic plus resistance spot welding (RSW) [7], laser penetration [8], barrel nitriding [9], friction welding [10], friction stir welding (FSW) [11], and friction stir spot welding (FSSW) techniques [12]. Nowadays, the most common techniques used in welding aluminum alloy with steel are FSW, FSSW, and RSW methods.…”

Section: Introductionmentioning

confidence: 99%

Friction Spot Lap Joining of Aluminum Alloy AA6061 to Pre-Holed and Threaded Carbon Steel AISI 1006

Ibrahim

Hussein

Jadee

2022

International Journal of Applied Mechanics and Engineering

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This work addresses to joining aluminum alloy AA6061 to carbon steel AISI 1006 sheets using the friction spot joining technique. The steel sheets were pre-holed and threaded with an internal M6 thread. The joining process was carried out by extruding the aluminum through the steel hole and thread using a rotating tool with friction between the tool and aluminum. Three process parameters were used: pre-heating time, rotating speed and plunging depth of the tool, with four levels for each parameter. The results indicated that the two materials joined by a micro-scale mechanical interlock at an interface line of a width ranged between 0.7 to ~ 2.5 mm. The joint’s shear force reached a minimum and maximum value of 2000 and 2500 N, respectively. The plunging depth was the most effective factor affecting the amount of the extruded aluminum and the joint’s shear force.

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Dissimilar metal joining of aluminum to steel by ultrasonic plus resistance spot welding - Microstructure and mechanical properties

Cited by 54 publications

References 31 publications

Micro Resistance Spot Welding Optimization for Ultra-Thin Mo-Re Sheet Used in TWT

Micro Resistance Spot Welding Optimization for Ultra-Thin Mo-Re Sheet Used in TWT

Plasma-Pulsed GMAW Hybrid Welding Process of 6061 Aluminum and Zinc-Coated Steel

Friction Spot Lap Joining of Aluminum Alloy AA6061 to Pre-Holed and Threaded Carbon Steel AISI 1006

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