A new physical simulation tool to predict the interface of dissimilar aluminum to steel welds performed by friction melt bonding

Abstract

Optimization of the intermetallic layer thickness and the suppression of interfacial defects are key elements to improve the load bearing capacity of dissimilar joints. However, till date we do not have a systematic tool to investigate the dissimilar joints and the intermetallic properties produced by a welding condition. Friction Melt Bonding (FMB) is a recently developed technique for joining dissimilar metals that also does not exempt to these challenges. The FMB of DP980 and Al6061-T6 is investigated using a new physical simulation tool, based on Gleeble thermo-mechanical simulator, to understand the effect of individual parameter on the intermetallic formation. The proposed method demonstrates its capability in reproducing the intermetallic characteristics, including the thickness of intermetallic bonding layer, the morphology and texture of its constituents (Fe2Al5 and Fe4Al13), as well as their nanohardness and reduced modulus. The advantages of physical simulation tool can enable novel developing routes for the development of dissimilar metal joining processes and facilitate to reach the requiring load bearing capacity of the joints.

High temperature in situ SEM assessment followed by ex situ AFM and EBSD investigation of the nucleation and early growth stages of Fe-Al intermetallics

“…Both θ-and η-grains are slightly elongated along the phase growth direction, presenting very similar average aspect ratios of 1.84 and 1.86, respectively. It should be noted that these values are much lower compared to those measured on columnar grains of both phases in the well-grown IM layer with the thickness of 38-40 µm [26,27]. As shown in Fig.…”

“…The developed IM in Fig. 3b clearly shows a preferential growth perpendicular to the interface, which may be attributed to the diffusion-controlled growth of η-phase [26]. 3a) and line L2 (marked in Fig.…”

Review on corrosion resistance of mild steels in liquid aluminum

“…2(a)). Numerous studies [3,7,10,19,[33][34][35][36][37][38][39] indicated that Fe2Al5 grows toward the matrix with a preferential growth orientation of [001]. It is found that Fe2Al5 has an orthogonal structure (a=0.7656 nm, b=0.6415 nm, c=0.4218 nm) with a 30% vacancy along the c-axis direction of [001], which is higher than those along the a-axis and b-axis, and thus it tends to grow along the c-axis.…”

Microstructure and Fatigue Behaviors of Dissimilar A6061/Galvannealed Steel Joints Fabricated by Friction Stir Spot Welding

“…Since it is difficult to make the whole body using Al alloys [ 4 ], the realization of a hybrid construction between steel and Al alloys that maintains their respective advantages, has attracted attention. In previous studies, various methods of Al/steel welding have been investigated: ultrasonic spot welding for 6061 Al alloy and AISI 304 stainless steel [ 5 ], MIG-TIG double-side arc welding for 5052 Al alloy and steel [ 6 ], explosive welding for 1230 Al alloy and AISI 321 stainless steel [ 7 ], resistance spot welding (RSW) for 6022 Al alloy and steel [ 8 ] and for 5052 Al alloy and GA590 steel [ 9 ], magnetic pulse welding for 5052 Al alloy and steel [ 10 ], friction melt bonding for 6061 Al alloy and DP980 steel [ 11 ], friction stir welding (FSW) for 5052 Al alloy and DP steel [ 12 ], etc.…”