Joining of aluminium alloy and galvanized steel using a controlled gas metal arc process

Laser and Gas Metal Arc Based Dissimilar Joining of Automotive Aluminium Alloys and Steel Sheets - A Review

“…Laser beam and pulsed current gas metal arc (GMA) based techniques could join thin metallic sheets of dissimilar materials at a very low power with moderate to reasonable high speed. The recently reported studies on application of laser beam and GMA based processes for joining of aluminium to steel sheets involved primarily the assessment of growth of intermetallic phase layer thickness with nature of IMCs at the joint interface and the corresponding joint strengths 6,7,10,11) . Laser beam and GMA based processes commonly employed pure Al, Al-Si, Al-Mg filler wires as well as without filler wire in joining aluminium to steel sheets [5][6][7][10][11][12][13][14] .…”

“…However, aluminium to steel joining is remain challenging due to their diverse thermo-physical properties, varying melting temperatures, poor solubility of aluminium in iron and in particular, formation of intermetallic phase layer with several Fe-Al brittle intermetallic compounds (IMC) 6) . Although presence of intermetallic phase layer is needed for the joint to form, however formation of thicker phase layer leads to embattlement of the joint [5][6][7] . Experimental studies indicate stringent control of the heat input is required to reduce the extent of formation of phase layer during joining of aluminium alloys and galvanized steel sheets 7) .…”

“…Although presence of intermetallic phase layer is needed for the joint to form, however formation of thicker phase layer leads to embattlement of the joint [5][6][7] . Experimental studies indicate stringent control of the heat input is required to reduce the extent of formation of phase layer during joining of aluminium alloys and galvanized steel sheets 7) .…”

“…Various processes such as resistance spot welding (RSW) 8) , friction stir welding (FSW) 9) , laser beam 10,11) and arc 6,7,[12][13][14][15] based joining techniques are attempted to join aluminium and steel with an aim to keep the heat input significantly low. Joining of complex contours us-ing FSW remained a problem while severe electrode wear due to chemical reaction between copper electrode and aluminium alloys inhibited use of RSW process in joining of aluminium alloys as well as of aluminium and steel 9,16) .…”

“…Joining of complex contours us-ing FSW remained a problem while severe electrode wear due to chemical reaction between copper electrode and aluminium alloys inhibited use of RSW process in joining of aluminium alloys as well as of aluminium and steel 9,16) . The use of laser and advanced pulsed current arc based joining processes is increasing in recent times due to their superior control over heat input with metal transfer rate, and flexibility to join out-of-position geometries [5][6][7]10,11) .…”