Interfacial characterization of joint between mild steel and aluminum alloy welded by resistance spot welding

Joining of dissimilar materials

“…Qiu et al [191] show a variation of IMC layer thickness peaking at approximately 6 mm in the centre of the weld nugget region with Fe 2 Al 5 adjacent to the cold-rolled steel and FeAl 3 adjacent to the A5052 Al alloy [188]. Wang et al [267] noted the same intermetallic formation for both A1050 and A2017 welded to coldrolled steel, though the Fe 2 Al 5 adjacent to the cold-rolled steel, was thinner for the A2017 alloy.…”

“…It can easily be automated, is very flexible, and since the weld gun electrodes are clamped, small gaps between the sheets can be levelled. A number of researchers have applied RSW to dissimilar Al-steel joints [91,163,181,191,232,257,267,297], as well as material combinations including Mg-steel [138], glasssteel [78], Cu-Ni plated steel [178], stainless steel-Ti [253], Ti-Al [193], and Al-Mg [90,106]. The benefits of enabling the RSW of Alsteel would be the re-use of existing infrastructure to join both like and dissimilar material combinations and the significant cost avoidance necessary to retool for a new joining process.…”

“…A number of researchers have investigated the formation of the intermetallic layer [191] and its effect upon weld strengths because of its deleterious effect. Zhang et al [298] used scanning electron microscopy of a partially failed tensile specimen to clearly show crack initiation at the interfacial IMC layer (chiefly Fe 2 Al 5 phase) and propagation through the IMC layer and partially through the Al alloy fusion zone adjacent to the IMC layer.…”

Effect of Resistance Spot Welding Parameters on AA1100 Aluminum Alloy and SGACD Zinc coated Lap Joint Properties

“…These light materials include high strength alloy, aluminum, magnesium, composite materials or plastic, etc. [1][2]. The weight reduction method also promotes a dissimilar material joint in car structure that could indicate the advantages of both metals and g ive a unique mechanical property [3].…”

“…[6]. This RSW process could also successfully produce the lap joint between aluminum and steel such as A5052/SPCC, SAE1008/5182-O [7], A5052/SUS304/SPCC [8][9][10][11], AISI316L/DIN 10130-99 [12], H220YD steel/6008-T66 [13], etc. Some RSW Al/Fe laps joint, such as SAE1008/5182-O lap joint indicated the static and dynamic joint strength under lap shear and cross tension test were slightly higher than that of the dissimilar SAE1008/5182-O lap joint that were produced by self-piercing rivet.…”