Interfacial microstructure and strength of steel/aluminum alloy joints welded by resistance spot welding with cover plate

Optimization of RSW parameters by joining galvanized steel HZ 220 BD-Z100 MB with aluminium AV 1050A

“…EDS analysis of selected cross-section locations (see Fig. 13 The structure of the studied transition zone between aluminium and steel and its thickness corresponds to the data published in the papers [17,18].…”

“…the joints [7,8,17,18]. Of course, they are also affected by the occurrence of defects at the interface between sheets, such as pores and lack of fusion (Figs.…”

Joining of dissimilar materials

“…They attribute this to the Cu alloying element diffusion reducing the Al atom activity coefficient thereby inhibiting the anisotropic growth of Fe 2 Al 5 . Qiu et al [189] noted similar retarded growth rates of Fe 2 Al 5 IMC layers in Al-austenitic stainless steel versus Al-cold rolled steel joints and attributed that to Cr atoms reducing the Al atom activity coefficient. On the other hand some alloying elements such as magnesium are very reactive and promote IMC growth, thereby reducing joint strength for example, from 1200 N with A1050 aluminium down to approximately 400 N with A5056 (4.5 at% Mg) welded to mild steel [106].…”

“…The idea here is to limit the amount of time molten aluminium interacts with the steel thereby minimizing the intermetallic layer thickness. Qiu et al [189] experimentally achieved a larger nugget and high tensile shear loads under relatively low welding current conditions for Al-Steel using a 1 mm thick cold rolled steel cover plate on the Al side. This is a result of an overall greater heat generation for a given weld schedule with a cover plate [192].…”

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

“…[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.…”