Enhancement of toughness of Al-to-steel Friction Melt Bonded welds via metallic interlayers

Jimenez-Mena, Norberto; Jacques, Pascal; Ding, Lipeng; Gauquelin, Nicolas; Schryvers, D.; Idrissi, Hosni; Delannay, Francis; Simar, Aude

doi:10.1016/j.msea.2018.10.101

Cited by 20 publications

(11 citation statements)

References 31 publications

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“…Al-steel joint having an interlayer of Co has been developed using friction melt bonded welding. However, Co2Al, Fe4Al13, CoAl3, and Fe2Al5 IMC were observed [8]. The Cr interlayer will also result in Al-Cr (such as Al7Cr, Al11Cr2, Al4Cr, Al9Cr4, Al8Cr5, AlCr2) and Fe-Cr-Al IMC [9].…”

Section: Intermetallic Compounds In Dissimiar Metals Welded Jointsmentioning

confidence: 98%

“…Hence, it is crucial to develop Al-steel joints free from IMCs. Research on suppressing IMCs by using a thin interlayer between Al and steel (Figure 1) is in progress [8].…”

Section: Intermetallic Compounds In Dissimiar Metals Welded Jointsmentioning

confidence: 99%

“…Hence, it is crucial to develop Al-steel joints free from IMCs. Research on suppressing IMCs by using a thin interlayer between Al and steel (Figure 1) is in progress [8]. Al-steel joint having an interlayer of Co has been developed using friction melt bonded welding.…”

Section: Intermetallic Compounds In Dissimiar Metals Welded Jointsmentioning

confidence: 99%

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Can High-Entropy Interlayers Develop Intermetallic-Free Welded Joints of Dissimilar Metals?

Waseem

2020

Eng

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The joining of two chemically dissimilar metals is a challenge due to the formation of hard and brittle intermetallic compounds (IMCs) in the diffusion layer. The joining of steel/Fe with aluminum (Al) and zirconium (Zr) alloy is particularly important for the automobile and nuclear industries, respectively. The Al–steel and Zr–steel joints produced by conventional fusion welding exhibit IMCs. The IMCs can enhance brittleness and cause catastrophic failure. This concept paper presents a novel idea of suppressing IMCs in welded joints using a high-entropy interlayer (HEI). It also discusses the potential candidates for HEIs and inspires research to exploit this new and promising research area.

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Section: Intermetallic Compounds In Dissimiar Metals Welded Jointsmentioning

confidence: 98%

“…Hence, it is crucial to develop Al-steel joints free from IMCs. Research on suppressing IMCs by using a thin interlayer between Al and steel (Figure 1) is in progress [8].…”

Section: Intermetallic Compounds In Dissimiar Metals Welded Jointsmentioning

confidence: 99%

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Can High-Entropy Interlayers Develop Intermetallic-Free Welded Joints of Dissimilar Metals?

Waseem

2020

Eng

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“…Therefore, mainly Fe-Al phases are formed, providing low mechanical properties and electrical conductivity. Application of interlayers, such as silver (FSW of AA6061-T6 with AISI 304 stainless steel [118]), cobalt (friction welding of AA1050 with DP600 steel [87,119]), and copper (LBW of 5052 with Q235 low carbon steel [120]) reported to be positive in reduction of the IMC layer thickness, providing improved mechanical properties, due to reduction in the hot tearing susceptibility. However, it may involve triple mixing of materials, having complex metallurgical reactions.…”

Section: Steel-aluminium With Interlayers and Coatingsmentioning

confidence: 99%

A Review on Laser-Assisted Joining of Aluminium Alloys to Other Metals

Bunaziv

Akselsen

Ren

et al. 2021

Metals

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Modern industry requires different advanced metallic alloys with specific properties since conventional steels cannot cover all requirements. Aluminium alloys are becoming more popular, due to their low weight, high corrosion resistance, and relatively high strength. They possess respectable electrical conductivity, and their application extends to the energy sector. There is a high demand in joining aluminium alloys with other metals, such as steels, copper, and titanium. The joining of two or more metals is challenging, due to formation of the intermetallic compound (IMC) layer with excessive brittleness. High differences in the thermophysical properties cause distortions, cracking, improper dilution, and numerous weld imperfections, having an adverse effect on strength. Laser beam as a high concentration energy source is an alternative welding method for highly conductive metals, with significant improvement in productivity, compared to conventional joining processes. It may provide lower heat input and reduce the thickness of the IMC layer. The laser beam can be combined with arc-forming hybrid processes for wider control over thermal cycle. Apart from the IMC layer thickness, there are many other factors that have a strong effect on the weld integrity; their optimisation and innovation is a key to successfully delivering high-quality joints.

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“…Morphology, thickness and properties of the IM layer play a key role in determining the bonding quality between steel and Al alloy [22][23][24]. There is a body of research focused on the growth kinetics of the IM layer at the steel/Al alloy interface.…”

Section: Introductionmentioning

confidence: 99%

A new physical simulation tool to predict the interface of dissimilar aluminum to steel welds performed by friction melt bonding

Sapanathan

Jimenez-Mena

Sabirov

et al. 2019

Journal of Materials Science & Technology

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Optimization of the intermetallic layer thickness and the suppression of interfacial defects are key elements to improve the load bearing capacity of dissimilar joints. However, till date we do not have a systematic tool to investigate the dissimilar joints and the intermetallic properties produced by a welding condition. Friction Melt Bonding (FMB) is a recently developed technique for joining dissimilar metals that also does not exempt to these challenges. The FMB of DP980 and Al6061-T6 is investigated using a new physical simulation tool, based on Gleeble thermo-mechanical simulator, to understand the effect of individual parameter on the intermetallic formation. The proposed method demonstrates its capability in reproducing the intermetallic characteristics, including the thickness of intermetallic bonding layer, the morphology and texture of its constituents (Fe2Al5 and Fe4Al13), as well as their nanohardness and reduced modulus. The advantages of physical simulation tool can enable novel developing routes for the development of dissimilar metal joining processes and facilitate to reach the requiring load bearing capacity of the joints.

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Enhancement of toughness of Al-to-steel Friction Melt Bonded welds via metallic interlayers

Cited by 20 publications

References 31 publications

Can High-Entropy Interlayers Develop Intermetallic-Free Welded Joints of Dissimilar Metals?

Can High-Entropy Interlayers Develop Intermetallic-Free Welded Joints of Dissimilar Metals?

A Review on Laser-Assisted Joining of Aluminium Alloys to Other Metals

A new physical simulation tool to predict the interface of dissimilar aluminum to steel welds performed by friction melt bonding

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