Microstructural and mechanical evolution of Al/steel interface with Fe2Al5 growth in resistance spot welding of aluminum to steel

Chen, Nannan; Wang, Min; Wang, Huiping; Wan, Zixuan; Carlson, Blair E.

doi:10.1016/j.jmapro.2018.06.024

Cited by 92 publications

(32 citation statements)

References 31 publications

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“…They used the resistance spot welding process for joining A5052 and DP 600 [10]. An additional layer of zinc or nickel between the two materials impacts the diffusion and the growth of intermetallic compounds [11,12]. However, in no joining process could the formation of the intermediate phases be completely inhibited, because all processes based on a molten phase for joining steel and aluminum.…”

Section: Introductionmentioning

confidence: 99%

Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging

2020

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In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving, composite hybrid forging has been developed. In this process, an aluminum solid part and a steel sheet were formed in a single step and joined at the same time with zinc as brazing material. For this purpose, the zinc was applied by hot dipping on the aluminum in order to produce a Brazing via these layers in a forming process, under pressure and heat. Due to the formed intermediate layer of zinc, the formation of the Fe-Al intermetallic phases and the contact corrosion are excluded. By determining the mathematical relationships between joining parameters and the mechanical properties of the joint, the strength of a specific joint geometry could be adjusted to reach the level of conventional joining techniques. In addition to the presentation of the joint properties, the influence of the joining process on the structure of the involved materials will be shown. Furthermore, the failure behavior under static tensile and shear stress will be shown.

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Section: Introductionmentioning

confidence: 99%

Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging

2020

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“…The HDDA is a composite process which includes hot-dip aluminizing and subsequent thermal diffusion treatment [9]. The diffusion treatment can improve the oxidation resistance [10,11] and wear resistance [12] of aluminized steel due to the formation of a Fe-Al intermetallic phase on the surface. The Fe-Al intermetallic coating formed during the diffusion process will react with oxygen to form a layer of alumina ceramic in the oxidation process, which can prevent cast iron from being oxidized.…”

Section: Introductionmentioning

confidence: 99%

Influence of Graphite Morphology on Phase, Microstructure, and Properties of Hot Dipping and Diffusion Aluminizing Coating on Flake/Spheroidal Graphite Cast Iron

Zhang¹,

Fan²,

Zhao³

et al. 2019

Metals

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The influence of graphite morphology on the phase, microstructure and properties of hot dipping and diffusion aluminizing (HDDA) coating on flake/spheroidal graphite cast iron (FC/FCD) was investigated. The microstructure and properties of the HDDA coatings on FC/FCD were determined by the graphite morphology. The outer and inner layers of the HDDA coating comprised the Fe2Al5 and FeAl phases, respectively. The outer layer of HDDA on FCD was dense and uniform; however, some pores of different sizes were found in the outer coating on FC, resulting in looser HDDA coating. Hence, the wear resistance of the HDDA coating on FC was worse than that of the coating on FCD. During oxidation, many continuous oxidation channels were formed from the coating surface to the matrix in the HDDA coating on FC, resulting in the oxidation of graphite in the HDDA coating and the matrix. However, only exposed spheroidal graphite was oxidized in the HDDA coating on FCD. Thus, the high-temperature oxidation resistance of the HDDA coating on FC was also worse than that of the coating on FCD.

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“…The weld zone contained intermetallic compounds which improved the joint efficiency. Chen et al (2018) found that the intermetallic compound growth took place over 900°C based on a numerical simulation of resistance spot welding of aluminium to steel. Oliveira et al (2019) joined aluminium and high strengths steel using hybrid joining technique of friction and spot welding.…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Spot lap joining of AA5052 to AISI 1006 by aluminium extrusion via friction forming technique

Hussein

Abdullah

Hussein

2019

MMMS

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Purpose The purpose of this paper is to join AA5052 to AISI 1006 steel sheets using the spot friction forming technique. Design/methodology/approach A steel sheet was pre-holed with a diameter of 4.8 mm and pre-threaded with a single internal M6 thread. Lap joint configuration was used so that the aluminium specimen was put over steel. A rotating tool with a 10 mm diameter was used for the joining process. A Taguchi method was used to design three process parameters (plunging tool depth, rotating speed and preheating time), with three levels for each parameter. The effect of the process parameters on the joint shear strength was analysed. The macrostructure, microstructure and scanning electron microscope of the joint were investigated. The temperature distribution during the joining process was recorded. Findings The formed aluminium was extruded through the steel hole and penetrated through the thread slot. A mechanical interlock was achieved between the extruded aluminium and the steel. The plunging depth of the tool exhibited a significant effect on the joint shear strength. The joint efficiency increased gradually as the plunging depth increased. Two modes of failure were found shear and pull-out. The maximum temperature during the process reached 50 per cent of aluminium’s melting point. Originality/value For the first time, AA5052 was joined with AISI 1006 steel using a friction spot forming technique with an excellent joint efficiency.

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Microstructural and mechanical evolution of Al/steel interface with Fe2Al5 growth in resistance spot welding of aluminum to steel

Cited by 92 publications

References 31 publications

Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging

Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging

Influence of Graphite Morphology on Phase, Microstructure, and Properties of Hot Dipping and Diffusion Aluminizing Coating on Flake/Spheroidal Graphite Cast Iron

Spot lap joining of AA5052 to AISI 1006 by aluminium extrusion via friction forming technique

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