Dissimilar Metals Laser Welding between DP1000 Steel and Aluminum Alloy 1050

Abstract

The welding of dissimilar metals was carried out using a pulsed Nd: YAG laser to join DP1000 steel and an aluminum alloy 1050 H111. Two sheets of each metal, with 30 × 14 × 1 mm3, were lap welded, since butt welding proved to be nearly impossible due to the huge thermal conductivity differences and melting temperature differences of these materials. The aim of this research was to find the optimal laser welding parameters based on the mechanical and microstructure investigations. Thus, the welded samples were then subjected to tensile testing to evaluate the quality of the joining operation. The best set of welding parameters was replicated, and the welding joint obtained using these proper parameters was carefully analyzed using optical and scanning electron microscopes. Despite the predicted difficulties of welding two distinct metals, good quality welded joints were achieved. Additionally, some samples performed satisfactorily well in the mechanical tests, reaching tensile strengths close to the original 1050 aluminum alloy.

Laser Welding of Transmitting High-Performance Engineering Thermoplastics

“…It has an average maximum power of 300 W and a peak pulse power of 12 kW. It has already been used to carry out other welding studies, from high-strength steels to dissimilar alloys [33,34], as well as to weld the two versions (white and black) of the material herein studied [28]. This machine makes it possible to set parameters such as the laser power, pulse duration, and frequency, percentage of overlapping between beams, and also their diameter.…”

Dissimilar Metal Welding

“…This special issue of Metals covers sixteen articles [5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20] focused on dissimilar metal joining techniques. Some of the published reports have confirmed the increasing interest in solid state welding processes, in particular friction based welding [6][7][8][9][10] and electromagnetic pulse welding [11,12], due to benefits related to the properties and achievable microstructure, and to energy and environmental considerations.…”

“…Some of the published reports have confirmed the increasing interest in solid state welding processes, in particular friction based welding [6][7][8][9][10] and electromagnetic pulse welding [11,12], due to benefits related to the properties and achievable microstructure, and to energy and environmental considerations. Other papers dealt with fusion welding techniques, mainly laser based [13][14][15][16], among others [5,17], and brazing processes [18,19]. Most of the applications are related to the automotive and aerospace sector, nevertheless dissimilar joints, characterized by improved fracture resistance, were indicated as an indispensable part of nuclear power plants for connecting the safe end (austenitic stainless steel 316L) to the pipe-nozzle (ferrite low-alloy steel A508) [20].…”

“…As far as dissimilar fusion welding processes are concerned, relevant efforts have been directed toward laser based methods [13][14][15][16]. Dual-beam laser welding has been investigated for dissimilar welding of steel/Al [13].…”

Microstructure and Mechanical Properties of Resistance Heat-Assisted High-Power Ultrasonic Dissimilar Welded Cu/Al Joint

“…Ultrasonic welding can produce welds faster and with less material loss than other common welding methods of dissimilar lap joints, such as laser welding (LW) [1,2] and friction stir welding (FSW) [3,4]. It also requires lower energy input than resistance spot welding (RSW) [5].…”