Interfacial characteristics and mechanical properties of aluminum / steel butt joints fabricated by a newly developed high-frequency electric cooperated arc welding-brazing process

Zheng, Yi; Huang, Jihua; Cheng, Zhi; Wang, Shifei; Yang, Jian; Chen, Shuhai; Zhao, Xingke

doi:10.1016/j.jmatprotec.2021.117317

Cited by 10 publications

(4 citation statements)

References 28 publications

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“…This is because the distinct interface between these alloys can cause the formation of weak metal connections, thermal stress buildup, solubility problems, and discrepancies in thermal properties. FGMs are a promising solution to these problems, as they allow a smooth transition of properties, eliminating abrupt changes at the interface [13,14]. Given their considerable capabilities, FGMs are found to be particularly useful in industrial settings (aerospace applications, energy industry, biomechanical applications, automotive industry, marine applications, etc.…”

Section: Introductionmentioning

confidence: 99%

A Systematic Study on Layer-Level Multi-Material Fabrication of Parts via Laser-Powder Bed Fusion Process

Angelastro,

Posa,

Errico

et al. 2023

Metals

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In this work, a systematic study was conducted on the fabrication of multi-material components obtained employing Laser-Powder Bed Fusion (L-PBF) technology. The idea of making multi-material components is a winning capability of additive technologies because it allows for the fabrication of Functionally Graded Materials (FGMs) with the customization of parts according to different required properties. This study aims to determine the ability of an inexpensive system, adaptable to the L-PBF machines already on the market, with a powder-spreading technique based on coaters or rollers, to produce parts with continuously variable properties in each layer. Also, the correlation between certain selectable factors in the production design and the result obtained in terms of metallurgical and mechanical properties and chemical composition was investigated. The factors studied were the relative position of the different materials within the powder chamber and the geometry of the equipment designed to produce the cFGMs components. The performed tests involved the use of two materials, a nickel-based superalloy, and a stainless steel, having different chemical, physical, and mechanical properties to obtain gradual property variations in the manufactured samples. Based on the results of post-process characterization obtained via metallographic, chemical, and mechanical analysis, the relative positions of the materials and the geometry of the developed equipment have a limited effect on the sample’s manufactured properties. The characteristics of the FGM zone depend on the nature of the employed powders, and its extent coincides with that defined during the design of the divider.

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Section: Introductionmentioning

confidence: 99%

A Systematic Study on Layer-Level Multi-Material Fabrication of Parts via Laser-Powder Bed Fusion Process

Angelastro,

Posa,

Errico

et al. 2023

Metals

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“…Currently, there are mainly three kinds of methods for Al/steel dissimilar joining. One is welding-brazing, in which lasers [6,7], arcs [8][9][10], plasma arcs [11], or their hybrids [12][13][14] are used as the heating source to melt aluminum, and the melted aluminum is spread onto the solid steel to form a brazed joint by solidification. However, brittle iron-aluminum intermetallic compounds (IMCs) are easily formed during the meltingsolidification process [6][7][8][9][10][11][12][13][14], resulting in relatively low strength of the brazed Al/steel joint.…”

Section: Introductionmentioning

confidence: 99%

“…One is welding-brazing, in which lasers [6,7], arcs [8][9][10], plasma arcs [11], or their hybrids [12][13][14] are used as the heating source to melt aluminum, and the melted aluminum is spread onto the solid steel to form a brazed joint by solidification. However, brittle iron-aluminum intermetallic compounds (IMCs) are easily formed during the meltingsolidification process [6][7][8][9][10][11][12][13][14], resulting in relatively low strength of the brazed Al/steel joint. The second is riveting [15,16], which can obtain high joint strength but the gas tightness is inadequate in some applications such as storage tanks.…”

Section: Introductionmentioning

confidence: 99%

Improved Mechanical Properties of SUS304/AA5083 Dissimilar Joint by Laser Ablation Pretreatment in Vortex- Friction Stir Lap Welding

Liu,

Luo,

Bao

et al. 2023

Crystals

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To obtain a high-quality Al/steel dissimilar joint, a micro-groove-assisted vortex-friction stir lap welding (MG-VFSLW) process was developed. Through prefabricating micro-grooves on the steel plate surface by laser ablation, high-quality mechanical interlock and metallurgical bonding were obtained simultaneously in the MG-VFSLW process. The weld formation, interface microstructure, mechanical properties, and failure mode in MG-VFSLW were studied by comparing them with those in VFSLW. The results showed that a line load of the AA5083/SUS304 dissimilar joint up to 485.9 N/mm was obtained by MG-VFSLW, which is 40.1% higher than that in VFSLW. Remarkable intermetallic compound layers and cracks were found in VFSLW. The cracks were closely related to the oxides on the interface. However, in MG-VFSLW, cross-riveting aluminum rivets and steel rivets were formed on the interface due to the micro-grooves and flashes made by the laser ablation. Good metallurgical bonding was also formed between AA5083 and SUS304. No remarkable intermetallic compound layers and cracks occurred. During the tensile shear tests, the aluminum rivets were cut off and some dimples and tear ridges existed on the fracture surface. In short, the high strength of the Al/steel lap joint in MG-VFSLW was attributed to the high-quality mechanical interlock and metallurgical bonding.

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“…A smaller temperature difference at the Al/steel interface could effectively improve the uniformity of the interfacial layer. Ye et al [ 25 ] found that the massive brittle IMCs in the Al/steel could be inhibited under low heat input. In addition to the heat input control, Rong et al [ 26 ] studied the growth kinetics of IMCs produced between molten steel and molten aluminum, and then proposed that the composition and morphology of IMCs were governed by interfacial reaction and diffusion process in the interface reaction.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Multiple Thermal Process on Microstructural Evolution and Mechanical Properties of Additive Manufactured Al/Steel Structure

2022

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Wire and arc additive manufacturing (WAAM) provides a convenient solution for the integrated design and manufacturing of Al/steel structures. The multiple thermal cycles inherent in WAAM can affect the Al/steel interface and ultimately the overall performance of the Al/steel structure. Herein, the evolution behavior of the Al/steel interface microstructure under different WAAM modes, number of thermal cycles, and interpass temperature is investigated. The results show that the process of heat accumulation plays an important role in the evolution of Al/steel interface. As the number of thermal cycles increases, the intermetallic compounds layer gradually transforms from the mainly τ5‐Al8Fe2Si phase to (Al, Si)13(Fe, Cr)4 phase. The rise of interpass temperature significantly aggravates the microstructural evolution process, but the final interface structure can be manipulated employing temperature control. When the interpass temperature is lower than 250 °C, the formation of the brittle Fe2Al5 phase is avoided. With the increase of thermal cycles, the shear strength of Al/steel additive specimens increases first, then decreases, and finally tends to be stable. The changes in shear strength are closely related to the interface microstructures.

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Interfacial characteristics and mechanical properties of aluminum / steel butt joints fabricated by a newly developed high-frequency electric cooperated arc welding-brazing process

Cited by 10 publications

References 28 publications

A Systematic Study on Layer-Level Multi-Material Fabrication of Parts via Laser-Powder Bed Fusion Process

A Systematic Study on Layer-Level Multi-Material Fabrication of Parts via Laser-Powder Bed Fusion Process

Improved Mechanical Properties of SUS304/AA5083 Dissimilar Joint by Laser Ablation Pretreatment in Vortex- Friction Stir Lap Welding

The Effect of Multiple Thermal Process on Microstructural Evolution and Mechanical Properties of Additive Manufactured Al/Steel Structure

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