The influence of reaction layer on the strength of aluminum/steel joint welded by resistance spot welding

Optimization of RSW parameters by joining galvanized steel HZ 220 BD-Z100 MB with aluminium AV 1050A

“…the joints [7,8,17,18]. Of course, they are also affected by the occurrence of defects at the interface between sheets, such as pores and lack of fusion (Figs.…”

“…Also, the melting temperature of zinc (419 • C), Table 1, as well as its evaporation temperature (907 • C) are significantly lower than the melting point of Fe (1538 • C). When galvanized steel sheet is melted, Zn evaporates, which may cause microstructural defects (e.g., pores) [7]. The creation of a metallurgical joint between steel and aluminium requires, in the first place, a detailed understanding of the properties of the materials.…”

Joining of dissimilar materials

“…Qiu et al [191] show a variation of IMC layer thickness peaking at approximately 6 mm in the centre of the weld nugget region with Fe 2 Al 5 adjacent to the cold-rolled steel and FeAl 3 adjacent to the A5052 Al alloy [188]. Wang et al [267] noted the same intermetallic formation for both A1050 and A2017 welded to coldrolled steel, though the Fe 2 Al 5 adjacent to the cold-rolled steel, was thinner for the A2017 alloy.…”

“…Thus, researchers need to understand the effect of IMC thickness and morphology on strength. Qui et al applied Electron Microprobe Analysis (EMPA) imaging of A5052 Al-cold rolled steel fracture surfaces to show that fracture occurred in the base Al material when the IMC layer was thinner than 1.5 mm and having a discontinuous morphology, but fractured in the reaction layer for greater thicknesses which had a continuous morphology [188]. However, within the range of discontinuous IMC, the tensile strength increased with increased discontinuous reaction layer fraction [190].…”

Effect of Resistance Spot Welding Parameters on AA1100 Aluminum Alloy and SGACD Zinc coated Lap Joint Properties

“…[6]. This RSW process could also successfully produce the lap joint between aluminum and steel such as A5052/SPCC, SAE1008/5182-O [7], A5052/SUS304/SPCC [8][9][10][11], AISI316L/DIN 10130-99 [12], H220YD steel/6008-T66 [13], etc. Some RSW Al/Fe laps joint, such as SAE1008/5182-O lap joint indicated the static and dynamic joint strength under lap shear and cross tension test were slightly higher than that of the dissimilar SAE1008/5182-O lap joint that were produced by self-piercing rivet.…”