Study of the brittleness mechanism of aluminum/steel laser welded joints with copper and vanadium interlayers

Zhang, Yuting; Wang, Weixiu; Li, Zhuoyu; Huang, Genzhe; Zhang, Hong; Fengde, Liu

doi:10.1016/j.optlastec.2023.109319

Cited by 5 publications

(2 citation statements)

References 47 publications

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“…In terms of physical characteristics, great differences exist between aluminum alloys and steel, such as melting point, electrical conductivity, thermal conductivity, and thermal expansion coefficient. Therefore, the formation of good welding between both materials is very difficult, resulting in brittle intermetallic compounds (IMCs) at the aluminum/steel interface during welding, adversely affecting the mechanical properties of aluminum/steel welded joints [2][3][4].…”

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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“…Generally, these components are manufactured through solid-state welding processes such as friction-stir welding (Ghosh et al , 2012), explosive welding (Saravanan and Raghukandan, 2022), electromagnetic welding (Kore et al , 2008) and ultrasonic welding (Satpathy et al , 2019). Sometimes laser welding has also been successfully performed for the development of highly functional SS–Al dissimilar joints (Chen et al , 2016; Yaochen et al , 2022; Zhang et al , 2023). However, these solid-state or laser assisted processes are way too costly in terms of equipment cost, operation cost and maintenance cost, which makes it economically infeasible for the industrial application (Frazier, 2014).…”

Section: Introductionmentioning

confidence: 99%

Influence of copper interlayer on the interface characteristics of stainless steel–aluminium transitional structure in wire arc directed energy deposition

Paul,

Mukherjee,

Sahu

2023

RPJ

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Purpose The purpose of this study is to investigate the deposition of SS–Al transitional wall using the wire arc directed energy deposition (WA-DED) process with a Cu interlayer. This study also aims to analyse the metallographic properties of the SS–Cu and Al–Cu interfaces and their mechanical properties. Design/methodology/approach The study used transitional deposition of SS–Al material over each other by incorporating Cu as interlayer between the two. The scanning electron microscope analysis, energy dispersive X-ray analysis, X-ray diffractometer analysis, tensile testing and micro-hardness measurement were performed to investigate the interface characteristics and mechanical properties of the SS–Al transitional wall. Findings The study discovered that the WA-DED process with a Cu interlayer worked well for the deposition of SS–Al transitional walls. The formation of solid solutions of Fe–Cu and Fe–Si was observed at the SS–Cu interface rather than intermetallic compounds (IMCs), according to the metallographic analysis. On the other hand, three different IMCs were formed at the Al–Cu interface, namely, Al–Cu, Al2Cu and Al4Cu9. The study also observed the formation of a lamellar structure of Al and Al2Cu at the hypereutectic phase. The mechanical testing revealed that the Al–Cu interface failed without significant deformation, i.e. < 4.73%, indicating the brittleness of the interface. Originality/value The study identified the formation of HCP–Fe at the SS–Cu interface, which has not been previously reported in additive manufacturing literature. Furthermore, the study observed the formation of a lamellar structure of Al and Al2Cu phase at the hypereutectic phase, which has not been previously reported in SS–Al transitional wall deposition.

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Magnetic and structural properties of nanostructured FeSn, FeSnTi, FeSnV and FeSnTiV alloys elaborated via ball milling process

Abada,

Younes,

Manseri

2023

J. Korean Phys. Soc.

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Study of the brittleness mechanism of aluminum/steel laser welded joints with copper and vanadium interlayers

Cited by 5 publications

References 47 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

Influence of copper interlayer on the interface characteristics of stainless steel–aluminium transitional structure in wire arc directed energy deposition

Magnetic and structural properties of nanostructured FeSn, FeSnTi, FeSnV and FeSnTiV alloys elaborated via ball milling process

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