Feasibility study of dissimilar joining of aluminum alloy 5052 to pure copper via thermo-compensated resistance spot welding

Zhang, Yu; Li, Yang; Luo, Zhen; Yuan, Tao; Bi, Jing; Wang, Zhengke; Wang, Zhi Ping; Chao, Yuh J.

doi:10.1016/j.matdes.2016.05.117

Cited by 40 publications

(16 citation statements)

References 37 publications

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“…Thermo-compensated DSW was employed to prevent surface oxides from adhering to the welding electrodes by balancing the thermal flow between dissimilar target materials [29,30]. A Cr-Ni-based process tape (PT3000) and a steel-based process tape (PT1407) were chosen as contact electrodes for the Al6061-T6 and GA340YC substrates, respectively, as shown in the schematic of the DSW simulator in Figure 2.…”

Section: Dsw and Accelerated Corrosion Testmentioning

confidence: 99%

Enhanced Long-Term Reliability of Seal DeltaSpot Welded Dissimilar Joint between 6061 Aluminum Alloy and Galvannealed Steel via Excimer Laser Irradiation

et al. 2021

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Structural-adhesive-assisted DeltaSpot welding was used to improve the weldability and mechanical properties of dissimilar joints between 6061 aluminum alloy and galvannealed HSLA steel. Evaluation of the spot-weld-bonded surfaces from lap shear tests after long-term exposure to chloride and a humid atmosphere (5% NaCl, 35 °C) indicated that the long-term mechanical reliability of the dissimilar weld in a corrosive environment depends strongly on the adhesive–Al6061 alloy bond strength. Corrosive electrolyte infiltrated the epoxy-based adhesive/Al alloy interface, disrupting the chemical interactions and decreasing the adhesion via anodic undercutting of the Al alloy. Due to localized electrochemical galvanic reactions, the surrounding nugget matrix suffered accelerated anodic dissolution, resulting in an Al6061-T6 alloy plate with degraded adhesive strength and mechanical properties. KrF excimer laser irradiation of the Al alloy before adhesive bonding removed the weakly bonded native oxidic overlayers and altered the substrate topography. This afforded a low electrolyte permeability and prevented adhesive delamination, thereby enhancing the long-term stability of the chemical interactions between the adhesive and Al alloy substrate. The results demonstrate the application of excimer laser irradiation as a simple and environmentally friendly processing technology for robust adhesion and reliable bonding between 6061 aluminum alloy and galvannealed steel.

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Section: Dsw and Accelerated Corrosion Testmentioning

confidence: 99%

Enhanced Long-Term Reliability of Seal DeltaSpot Welded Dissimilar Joint between 6061 Aluminum Alloy and Galvannealed Steel via Excimer Laser Irradiation

et al. 2021

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“…2. , (2) where μ N is the average values from the nested design, β j ~ N(0, σ β ) and α(β) i(j) ~ N(0, σ α(β) ) are the random and independent variables for operator and for parts nested within operators, respectively. The ε ijk ~ N(0, σ ε ) is the estimated error term.…”

Section: Analysis Of Variance (Anova)mentioning

confidence: 99%

“…Resistance spot welding (RSW) is a structural joint technique widely used in the automotive sector [1]. RSW is highlighted among welding processes due to its features that favor the industry such as agile operation, which is easily suitable for automatic processes, simple handling, diverse applications and low cost [2] to [4]. Because of its wide applicability and importance, new methodologies for parameter adjustment have been applied to RSW improvement, contributing to the process control and capability.…”

Section: Introductionmentioning

confidence: 99%

A Gage Study Applied in Shear Test to Identify Variation Causes from a Resistance Spot Welding Measure System

2018

SV-JME

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Resistance welding processes, especially spot welding, have wide applicability in the industry, especially in the automotive sector, due to its fast execution and the non-use of consumables. In addition, the search for quality improvement of the final product is incessant and, in a capable process, there should be no error related to the measurements. In this study, the NGR&R was used by the ANOVA method to identify the variation components of the measurement system in the shear test for two quality characteristics: tensile-shear strength and ultimate strain. The experiments were conducted on a hot dip galvanized steel by using design of experiments to select the parts in order to represent the real amplitude of the process. From the results it was possible to verify that one of the destructive test machines used in this study has a strong variability, evidencing that some adjustments and improvements are necessary in the coupling of the specimens for steels with coating layers (such as galvanized steel, which has a layer of zinc).

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“…Due to the properties of the two materials (different melting temperatures, different coefficients of thermal expansion, and different thermal conductivities, as well as the tendency to form brittle, intermetallic compounds with high specific electrical resistance), the manufacturing of these mixed joints is a challenge for joining technologies [1]; [3]; [4]; [5]. The use of friction-based solidstate welding processes such as friction stir welding (FSW) [6]; [7]; [8]; [9]; [10]; [11]; [12]; [13] or ultrasonic welding (USW) [14]; [15]; [16]; [17]; [18]; [19]; [20] can produce dissimilar material connections in several material combinations including Al and Cu. The formation of brittle intermetallic phases such as AlCu and Al 4 Cu 9 can be reduced when using ultrasonic welding by keeping the joining zone temperatures below the liquidus temperature of the joining partners [14]; [21].…”

Section: Introductionmentioning

confidence: 99%

Influence of different Ni coatings on the long-term behavior of ultrasonic welded EN AW 1370 cable/EN CW 004A arrestor dissimilar joints

2020

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The increasing demand for energy-efficient vehicles requires suitable methods for cost and weight reduction. This can be achieved by the replacement of copper by aluminum, in particular for the on-board power systems. However, the complete substitution is restricted by the mechanical and physical material properties of aluminum as well as challenges in the aluminum copper interface. The challenges concern the corrosion vulnerability and the occurrence of brittle intermetallic compounds (IMC) which can negatively influence the mechanical properties and the electrical conductivity. Therefore, current investigations focus on the one hand on the realization of dissimilar aluminum copper joints by suitable joining technologies, like ultrasonic welding, and on the other hand on the assurance of a sufficient prevention against harmful corrosion effects. In cases where the joint cannot be protected against corrosion by sealing, nickel coatings can be used to protect the joint. In the present study, the influence of electroless, electroplated, and sulfamate nickel coatings was investigated regarding the long-term stability. The joints were performed as industry-related arrester connections, consisting of EN AW 1370 cables and EN CW 004A terminals. The samples were exposed to corrosive as well as electrical, thermal, and mechanical stress tests according to current standards and regulations.

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Feasibility study of dissimilar joining of aluminum alloy 5052 to pure copper via thermo-compensated resistance spot welding

Cited by 40 publications

References 37 publications

Enhanced Long-Term Reliability of Seal DeltaSpot Welded Dissimilar Joint between 6061 Aluminum Alloy and Galvannealed Steel via Excimer Laser Irradiation

Enhanced Long-Term Reliability of Seal DeltaSpot Welded Dissimilar Joint between 6061 Aluminum Alloy and Galvannealed Steel via Excimer Laser Irradiation

A Gage Study Applied in Shear Test to Identify Variation Causes from a Resistance Spot Welding Measure System

Influence of different Ni coatings on the long-term behavior of ultrasonic welded EN AW 1370 cable/EN CW 004A arrestor dissimilar joints

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