Review of Aluminum-To-Steel Welding Technologies for Car-Body Applications

Gullino, Alessio; Matteis, Paolo; D’Aiuto, Fabio

doi:10.3390/met9030315

Cited by 130 publications

(72 citation statements)

References 106 publications

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“…In this study, AA6063 (non-ferrous aluminium alloy) was to join to SS304L (Ferrous austenitic stainless steel) by direct drive friction welding. The joint made of aluminium and stainless steel is used in applications such as automobiles, cryogenic engines, and spacecraft [30,31]. The chemical compositions of both the base metals were determined by optical emission spectrometer (OES) at room temperature and shown in Table 1.…”

Section: Methodsmentioning

confidence: 99%

Experimental study on the effect of silver, nickel and chromium interlayers and upset pressure in joining SS304L-AA6063 alloys through direct drive friction welding process

Murugan

Sathiya

Haq

2020

J Braz. Soc. Mech. Sci. Eng.

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Joining of dissimilar alloys is demanded industrial applications and is effectively possible with the friction welding (FW) process. In this work, SS304L alloy rods were electroplated with silver (Ag), nickel (Ni) and chromium (Cr) and joined with AA6063 at various upset pressures (UP) (18, 21, 24 MPa) through friction welding process. The interlayer produced by the electroplating process was considered as the third element between AA6063 and SS304L during the FW. The results obtained through weld microstructures, fracture images, energy-dispersive X-ray spectroscopy, tensile properties, joint efficiency, Vickers microhardness and Charpy V-notch test of the fabricated dissimilar joints are discussed here. Fracture study showed the dimple fracture. The maximum strength and axial shortening were obtained as 216 ± 8 MPa and 27 mm, respectively. Maximum joint efficiency was achieved for Cr interlayer as 105 ± 4% at 24 MPa UP, which also showed a 1.79 tensile-to-yield (TS/YS) ratio. UP of 24 MPa improved ductile nature of joint. Ag and Ni joints rendered poor elongation. FW of chromium-electroplated specimen gave maximum weld performance than that of others. Ag interlayer at 18 MPa UP showed good hardness. Maximum impact energy observed by Cr at 24 MPa UP was 35 J. The novelty of the work is to frictionally weld the dissimilar metals of ϕ12 mm rods with Ag, Ni, Cr interlayer at welding pressures in view of safety and energy consumption. There were the changes in the microstructure and mechanical properties of joints when the interlayers, UPs changed.

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Section: Methodsmentioning

confidence: 99%

Experimental study on the effect of silver, nickel and chromium interlayers and upset pressure in joining SS304L-AA6063 alloys through direct drive friction welding process

Murugan

Sathiya

Haq

2020

J Braz. Soc. Mech. Sci. Eng.

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“…Due to its high specific strength, good corrosion resistance, and low cost, aluminum and its alloys have great potential to replace the conventional steel component. As a result, the sound aluminum and steel welded joint has gained extensive attention [1]. However, distinct differences in thermal physical properties and the formations of brittle intermetallic compounds (IMCs) at the bonding interface are obstacles to achieve effective connection [2].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Al/Steel Butt Joint by Hybrid CMT Welding with External Axial Magnetic Field

Kang

Liu

et al. 2020

Materials

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The 6061 aluminum alloy and 304 stainless steel were welded by hybrid cold metal transfer (CMT) welding with external axial magnetic field. The effects of magnetic intensity and frequency on joint microstructure and mechanical properties were studied. It was found that the magnetic field can promote the spreading of aluminum weld metal on the steel surface and thus increase the bonding area of Al/steel butt joint. The welding process stability improved, while the wetting behavior worsened with the introduction of alternating frequencies. The thickness of the intermetallic compound (IMC) layer at Al/steel interface was reduced to 3 μm with the coil current of 2 A. The application of the magnetic field promoted the aggregation of Si atoms at the interface and inhibited the formation of brittle (Al, Si)13Fe4 phase. The fracture paths were transformed from (Al, Si)13Fe4 layer to Al8Fe2Si layer with the application of the magnetic field. The maximum tensile strength reached 130.2 MPa, an increase of 61.6% in comparison to the normal CMT process.

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“…Sustainable manufacturing has compelled the aerospace and automotive industries to reduce gas emissions and energy consumption. As a result, industries have been reducing the overall weight of products, without compromising quality and performance, by using low density and high resistant parts made of aluminum alloys and steels [1,2]. However, the difficulty in joining aluminum alloys and steels has limited the widespread usage of Al/steel components.…”

Section: Introductionmentioning

confidence: 99%

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Safeen

Spena

2019

Metals

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Joining of aluminum alloys through friction stir welding (FSW) is effectively employed in several industries (e.g., aeronautics and aerospace) since it guarantees proper weld strength as compared to other joining technologies. Contrarily, dissimilar FSW of aluminum alloys and steels often poses important issues in the selection of welding parameters due to the difficulty to join different materials. Improper welding parameters give rise to the formation of intermetallic compounds, and internal and external defects (e.g., tunnel formation, voids, surface grooves, and flash). Intermetallic compounds are brittle precipitates of Al/Fe, which chiefly initiate crack nucleation, whereas internal and external defects mainly act as stress concentration factors. All these features significantly reduce joint strength under static and dynamic loading conditions. With reference to the literature, the influence of main welding parameters (rotational speed, welding speed, tool geometry, tilt angle, offset distance, and plunge depth) on the formation of intermetallic compounds and defects in FSW of aluminum alloys and steels is discussed here. Possible countermeasures to avoid or limit the above-mentioned issues are also summarily reported.

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Review of Aluminum-To-Steel Welding Technologies for Car-Body Applications

Cited by 130 publications

References 106 publications

Experimental study on the effect of silver, nickel and chromium interlayers and upset pressure in joining SS304L-AA6063 alloys through direct drive friction welding process

Experimental study on the effect of silver, nickel and chromium interlayers and upset pressure in joining SS304L-AA6063 alloys through direct drive friction welding process

Microstructure and Mechanical Properties of Al/Steel Butt Joint by Hybrid CMT Welding with External Axial Magnetic Field

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

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