On the interplay between intermetallic controlled growth and hot tearing susceptibility in Al-to-steel welding with additional interlayers

Jimenez-Mena, Norberto; Simar, Aude; Jacques, Pascal

doi:10.1016/j.matdes.2019.107958

Cited by 12 publications

(6 citation statements)

References 39 publications

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“…(A-A 1 ): The profile technical literature shows significant differences between the values of the diffusion coefficients of aluminum in nickel [ 30 , 31 ], and vice versa [ 32 , 33 , 34 ], as shown in Table 1 , being about eight orders of magnitude if the phenomenon occurs below the Al melting temperature, and six orders for temperatures above this value.…”

Section: Resultsmentioning

confidence: 99%

Aluminide Diffusion Coatings on IN 718 by Pack Cementation

2022

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This paper addressed the issues of both direct and indirect synthesis of Ni aluminides by pack cementation (pure Ni and IN 718 superalloy). On the Al-Ni diffusion twosome under pressure, at temperatures below and above the Al melting temperature, the appearance and evolution of diffusion porosity because of the Kirkendall–Frenkel effect manifestation was highlighted. It has been confirmed that, as the temperature rises above the Al melting temperature, the porosity decreases. Nickel-based superalloys, and in particular IN 718, significantly increase their performance by increasing the aluminides proportion in the top diffusion coating. This is made possible by changing the value of the Al and Ni weight percentage ratio in this area (noted as Al/Ni). In the case of the diffusion twosome between IN 718 and pack aluminizing mixtures, having in their composition as active components Al powder, Ferroaluminum (FeAl40) or mixtures of Al and Fe powders, at processing temperatures above the Al melting temperature, by modifying the active component of the mixture, substantial changes in the Al/Ni values were observed, as well as in the maximum %Al in the diffusion coating and of its thickness. It was found that, when switching from Al to FeAl40 or powder mixture (Al + Fe), the Al/Ni value changes between 3.43 and 1.01, from initial subunit values. The experiments confirmed that the highest %Al in the top aluminized diffusion coating, for IN 718, was obtained if the powder mixture contained 66.34 wt.% Al.

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Section: Resultsmentioning

confidence: 99%

Aluminide Diffusion Coatings on IN 718 by Pack Cementation

2022

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“…Image pro plus 6.0 software is used to count the percentage of microcracks in the total number of pixels among the whole SEM image. The solid fractions of alloys plotted as functions of temperature were calculated using Factsage 7.1 software based on the Scheil-Gulliver model [10][11][12][15][16][17].…”

Section: Methodsmentioning

confidence: 99%

Reducing welding hot cracking of high-strength novel Al–Mg–Zn–Cu alloys based on the prediction of the T-shaped device

Pan

Zhang

Liu

et al. 2020

Science and Technology of Welding and Joining

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The higher hot cracking tendency during fusion welding in traditional high-strength 7000 series alloys has been an obstacle for its further application. In this study, the cracking susceptibility can be suppressed by fabricating Al-Mg-Zn-Cu alloys with Zn/Mg ≤ 1 and Cu/Mg ≤ 0.25 while simultaneously maintaining the high strength. A T-shaped device combined with nonequilibrium solidification is developed to simulate the solidification during fusion welding, and it is effective to predict the shrinkage load, temperature and solid fraction. The effect of solidification temperature range, the amount of eutectics at the terminal stage of solidification and the shrinkage load during solidification on the hot cracking susceptibility are discussed in detail.

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“…Both Al and steel have cubic crystal structure, and thus, substitutional diffusion is possible when Al atoms replace Fe atoms within the lattice at sufficiently high temperatures, typically in the range of 600-650 • C [5]. In this interlayer, large amounts of different IMCs (iron aluminides) are developed, and subsequently, they may deteriorate the mechanical properties [87]. The binary Fe-Al diagram was proposed by Kattner and Burton in 1992 [88] and is presented in Figure 9.…”

Section: Formation and Growth Of Fe-al Imc Layermentioning

confidence: 99%

“…The Ni interlayer was shown to be positive for toughness in friction welding of Al to stainless steel [117]. Friction melt bonding was successfully used between high-strength steel and AA1050, using the Ni interlayer of 10 µm, resulting in significant reduction in the Fe-Al IMC layer thickness by 90% [87]. Dissolution of the Ni interlayer in liquid Al provided hot tearing on the solidified Al side close to the IMC layer.…”

Section: Steel-aluminium With Interlayers and Coatingsmentioning

confidence: 99%

“…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%

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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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On the interplay between intermetallic controlled growth and hot tearing susceptibility in Al-to-steel welding with additional interlayers

Cited by 12 publications

References 39 publications

Aluminide Diffusion Coatings on IN 718 by Pack Cementation

Aluminide Diffusion Coatings on IN 718 by Pack Cementation

Reducing welding hot cracking of high-strength novel Al–Mg–Zn–Cu alloys based on the prediction of the T-shaped device

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

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