Optimised design of electrode morphology for novel dissimilar resistance spot welding of aluminium alloy and galvanised high strength steel

Microstructure and mechanical properties of electron beam welded dissimilar steel to Fe–Al alloy joints

“…Addition of 7-8% aluminium reduces the density of steel by about 17% [5]. However, forming and welding of low density steels to other car body parts made of different alloy materials especially with steel parts is challenging due to the different physical, mechanical and metallurgical properties of dissimilar metals [6]. Arc welding processes which operates at very high heat input in comparison to EBW, favours the formation of different brittle Fe-Al intermetallics at the weld interface which deteriorates mechanical properties of weld dissimilar joints [7].…”

Effect of Microstructure and Texture on Mechanical Properties of Resistance Spot Welded High Strength Steel 22MnB5 and 5A06 Aluminium Alloy

“…A key observation of resistance spot welding of Al and steel include investigating on the intermetallic compound (IMC) layer formed at the welding interface, microstructure and mechanical properties of the welded spots [6][7][8][9][10][11][12][13][14]. A study of resistance spot welded (RSWed) Al and steel by Oikawa et al [6] reported that the thickness of the IMC layer increased with increasing welding current, in addition, Qiu et al [7][8][9] found that tensile shear strength decreased with increasing welding current and the tensile shear strength decreased with increasing thickness of the IMC layers [10,11].…”

Effect of Steel Galvanization on the Microstructure and Mechanical Performances of Planar Magnetic Pulse Welds of Aluminum and Steel

“…The high chemical affinity of these materials [4] is another key difficulty for welding because it causes the formation of intermetallic compounds (IMCs). [2,5] Many investigations report welding of Al to galvanized or bare steel, for instance, (1) in the liquid state through various processes, such as metal arc joining, [6][7][8][9][10][11][12][13][14] cold metal transfer, [15,16] resistance spot welding, [17][18][19][20][21][22][23][24][25] electric discharge bonding, [26] electron beam welding, [27,28] explosive welding, [29][30][31] laser welding, [1][2][3][32][33][34][35][36][37][38][39][40][41][42][43][44] laser [45][46]…”