Process optimization of aluminum/steel resistance spot welding based on dynamic resistance analysis

Zhou, Kang; Wang, Gang; Ren, Baokai; Yu, Wenxiao; Ivanov, Mikhail

doi:10.1007/s10853-023-09157-0

Cited by 5 publications

(2 citation statements)

References 49 publications

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“…Numerous studies have so far been conducted on the RSW technology of dissimilar metals of aluminum alloy and high-strength steel [7][8][9]. Unlike arc welding and laser welding, the RSW does not require the use of filler wire.…”

Section: Introductionmentioning

confidence: 99%

Microstructures and properties of 7075 aluminum alloy and CP780 steel resistance spot welded joint assisted by magnetic field

Zhu,

Li,

Liu

et al. 2024

Mater. Res. Express

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Joining steel and aluminum is vital for lightweight automobile but still challenging due to their different physical properties. Herein, resistance spot welding tests were performed on CP780 high-strength steel (thickness 1mm) and 7075 aluminum alloy (thickness 1.5mm) dissimilar metals under steady-state magnetic field. The influences of magnetic field (B=40mT) on the structure of welded joints, the phase composition/content of intermetallic compounds, and tensile properties of welded joints were analyzed under different welding current conditions (I =9kA,10kA, 11kA, and 12kA). At the same welding current, the Lorentz force generated by the additional magnetic field promoted the outward circumferential movement of the molten metal in the weld along the horizontal surface , as well as increased the diameter of the Fe/Al contact interface in the weld nugget along the horizontal direction , conducive to the effective utilization of heat of the resistance spot welding. Except under (11kA-0mT) and (11kA-40mT), welded joints under other welding parameters displayed a few welding defects, such as incomplete fusion and shrinkage cavity formed at the cross-section of the welded joints. Therefore, the synergism between the magnetic field and appropriate welding current held important roles in the formation of welded joints without obvious welding defects. The intermetallic compounds of all the welds were mainly composed of (Fe, Si)Al2 and (Fe, Si)Al5. Meanwhile, the thickness and content of the intermetallic compounds layer reduced under a magnetic field at the same welding current, significantly improving the tensile properties of the welded joints. The comprehensive properties of welded joints were the best under 11kA-40mT, with an average shear force increase from 3.02kN to 3.49kN (15.56%) and an average displacement increase from 1.01mm to 1.22mm (20.79%). Overall, the proposed dissimilar aluminum/steel resistance spot welded joint assisted by magnetic field looks promising for lightweight automobile use.

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Section: Introductionmentioning

confidence: 99%

Microstructures and properties of 7075 aluminum alloy and CP780 steel resistance spot welded joint assisted by magnetic field

Zhu,

Li,

Liu

et al. 2024

Mater. Res. Express

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show abstract

“…In many joining techniques, resistance spot welding (RSW) is one of the most promising candidates due to its high flexibility and efficiency [ 6 , 7 ]. The high tensile and fatigue properties of the Al alloy/steel joints can be achieved by using the optimized RSW joining technique [ 8 , 9 , 10 ]. However, the Al alloy/steel RSW joint is still susceptible to corrosion and joint strength degradation in an aggressive environment due to the complicated microstructure and intrinsic differences in the electrochemical corrosion properties at the joint interface [ 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Corrosion Behavior and Mechanical Property of 5182 Aluminum/DP780 Steel Resistance Spot Welding Joints

Shi,

Zhang,

et al. 2024

Materials

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Corrosion behavior is critical to the application of lightweight aluminum/steel joints using new resistance spot welding (RSW) technology. The study investigated the corrosion mechanism and the shear strength of RSW joints comprising 1.2 mm 5182 aluminum and 1.5 mm DP780 galvanized steel. Electrochemical corrosion tests were conducted on the base materials and various positions of the welds in a 3.5% NaCl solution. This result revealed that the corrosion susceptibility of the interfacial intermetallic compound (IMC) layer was not accelerated by the aluminum nugget because of the noble corrosion potential. Subsequently, the spray acceleration test was employed to investigate the corrosion mechanism. It is noteworthy that microcracks, as well as regions enriched with silicon and oxygen at the interface front, are preferential to corrosion during salt spray exposure, instead of the IMC layer. Moreover, the shear strength of the joints decreases with the reduction in the effective joint area after the salt spray exposure of the weld joints. This research systematically explored the corrosion behavior and its relationship with the mechanical properties of Al alloy/steel RSW joints.

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Multi-objective optimization of T-shaped bilateral laser welding parameters based on NSGA-II and MOPSO

Tan,

Zhu,

Tian

et al. 2024

J Mater Sci

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Process optimization of aluminum/steel resistance spot welding based on dynamic resistance analysis

Cited by 5 publications

References 49 publications

Microstructures and properties of 7075 aluminum alloy and CP780 steel resistance spot welded joint assisted by magnetic field

Microstructures and properties of 7075 aluminum alloy and CP780 steel resistance spot welded joint assisted by magnetic field

Corrosion Behavior and Mechanical Property of 5182 Aluminum/DP780 Steel Resistance Spot Welding Joints

Multi-objective optimization of T-shaped bilateral laser welding parameters based on NSGA-II and MOPSO

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