Interfacial microstructure and mechanical properties of aluminium–zinc-coated steel joints made by a modified metal inert gas welding–brazing process

Zhang, H.T.; Feng, Jia; He, Peng; Hackl, Heinz

doi:10.1016/j.matchar.2006.07.008

Cited by 151 publications

(89 citation statements)

References 9 publications

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“…SEM can be useful to investigate the morphology of surface and crack patterns [229,261] as well as analysing the microstructure and thickness of IMC [293]. XPS can be used to investigate characteristics of bonding in the metal-polymer interface [94].…”

Section: Inspection Methodsmentioning

confidence: 99%

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Joining of dissimilar materials

2015

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Section: Inspection Methodsmentioning

confidence: 99%

“…Zhang et al [293] used EDX analysis to determine phases of the intermetallic compound layer after welding-brazing of aluminium with steel. Qi and Song [187] used SEM, EDS and XRD to investigate fracture surface and phases generated at the interface of the Mg alloy/Ni interlayer [187].…”

Section: Inspection Methodsmentioning

confidence: 99%

Joining of dissimilar materials

2015

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“…It is commonly known that brittle materials generally fail in tension, while ductile materials generally fail in shear [39]. Due to the brittle IMC layer of the Al-GI group being parallel to the loading direction, it withstood the shear loading until the ductile FZ-HAZ region of aluminium, having a smaller cross-sectional surface, yielded [19,40,41]. The results of the shear test are shown in Figure 5.…”

Section: Fracture and Mechanical Properties Analysismentioning

confidence: 99%

Lap joint dissimilar welding of aluminium AA6061 and galvanized iron using TIG welding

Shah¹,

Mohamad²,

Yaakob³

et al. 2016

J. Mech, Eng, Sci.

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In this paper, aluminium AA6061-O and galvanized iron were lap-joined using tungsten inert gas (TIG) welding. The experiments were conducted using Si-rich filler metals ER4043 (Si 5 wt.%) and ER4047 (Si 12 wt.%). The mechanical properties and the microstructure of the samples were analysed using dye penetrant non-destructive tests (NDT), optical microscope observation and shear tests. All samples showed good quality joints, with Al-GI specimens showing better quality. Through optical microscope observation, the intermetallic compounds (IMC) of specimens using ER4043 fillers show a thin IMC layer ranging from 4 µm to 7 µm, compared to ER4047 samples which ranged between 20 µm and 40 µm. The shear tests show that the GI-Al group fractured at the IMC layer, while the Al-GI group fractured at the FZ-HAZ aluminium matrix. The highest shear strength value obtained was 89.82 MPa and 76.59 MPa for the Al-GI and GI-Al positions, respectively. It can be concluded that the GI-Al (galvanized iron on top and aluminium at the bottom) configuration with filler type ER4043 (Si 5 wt.%) has the optimum mechanical properties with a thin IMC layer and tensile strength of 76.59 MPa.

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“…[9][10][11] An opportunity for joining particularly thin metal sheets by combining the advantages of both fusion and solid-state welding offers the Cold Metal Transfer (CMT) process developed by Fronius. [12] The CMT process enables spatter-free joining of similar metals, e.g., Al-Al bead-on-plate [13][14][15] or butt welding, [16] as well as joining of dissimilar metals, e.g., Al-steel butt welding with tapered steel sheet edges, [17][18][19] overlap welding, [20][21][22][23][24][25][26][27][28][29] or even spot welding. [30][31][32] In comparison with conventional gas metal arc (GMA) welding processes, the heat input of the CMT process is significantly reduced.…”

Section: Introductionmentioning

confidence: 99%

“…[20,21] Among the Al x Fe y phases listed in the binary Al-Fe phase diagram, [35] two main phases were identified in laboratory experiments to form at the interface between solid iron or steel and liquid aluminum or its alloys: Al 5 Fe 2 as the major g-phase [36][37][38] together with Al 3 Fe (also referred to as Al 13 Fe 4 ) as the minor h-phase. [39][40][41][42][43][44][45][46][47][48][49][50][51][52][53][54][55] Both [17][18][19]21,24,27,29] or at least either one [22,23] of these two phases were also found to form during dissimilar CMT welding of aluminum alloys with steel. These experimental studies also show that the interfaces are typically tongue-like between Al 5 Fe 2 and steel, whereas they are finely serrated between Al 3 Fe and aluminum.…”

Section: Introductionmentioning

confidence: 99%

Influence of Filler Alloy Composition and Process Parameters on the Intermetallic Layer Thickness in Single-Sided Cold Metal Transfer Welding of Aluminum-Steel Blanks

Silvayeh

Vallant

Sommitsch

et al. 2017

Metall Mater Trans A

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Hybrid components made of aluminum alloys and high-strength steels are typically used in automotive lightweight applications. Dissimilar joining of these materials is quite challenging; however, it is mandatory in order to produce multimaterial car body structures. Since especially welding of tailored blanks is of utmost interest, single-sided Cold Metal Transfer butt welding of thin sheets of aluminum alloy EN AW 6014 T4 and galvanized dual-phase steel HCT 450 X + ZE 75/75 was experimentally investigated in this study. The influence of different filler alloy compositions and welding process parameters on the thickness of the intermetallic layer, which forms between the weld seam and the steel sheet, was studied. The microstructures of the weld seam and of the intermetallic layer were characterized using conventional optical light microscopy and scanning electron microscopy. The results reveal that increasing the heat input and decreasing the cooling intensity tend to increase the layer thickness. The silicon content of the filler alloy has the strongest influence on the thickness of the intermetallic layer, whereas the magnesium and scandium contents of the filler alloy influence the cracking tendency. The layer thickness is not uniform and shows spatial variations along the bonding interface. The thinnest intermetallic layer (mean thickness < 4 lm) is obtained using the silicon-rich filler Al-3Si-1Mn, but the layer is more than twice as thick when different low-silicon fillers are used.

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Interfacial microstructure and mechanical properties of aluminium–zinc-coated steel joints made by a modified metal inert gas welding–brazing process

Cited by 151 publications

References 9 publications

Joining of dissimilar materials

Joining of dissimilar materials

Lap joint dissimilar welding of aluminium AA6061 and galvanized iron using TIG welding

Influence of Filler Alloy Composition and Process Parameters on the Intermetallic Layer Thickness in Single-Sided Cold Metal Transfer Welding of Aluminum-Steel Blanks

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