Abstract
Al-steel joining has a lot of use in the automotive and aerospace industries since it saves a lot of weight. The materials' physical, thermal, and metallurgical qualities differed significantly, making connecting this combination difficult. This article provides a comprehensive overview of the Al-steel joining processes. The fundamental reason for the problem in fusion joining operations is the formation of a thick intermetallic compound (IMC) layer and additional difficulties related to solidification. The effects of heat input, wettability, and IMC layer on joint formation are summarised in this article. To achieve a good joint, numerous elements like heat generation, IMC formation, and process parameters must be critically balanced in solid-state joining processes. The effects of process parameters in friction stir welding (FSW) techniques on joint's mechanical and metallographic soundness are explored in this work. Because of the steel's higher strength, there have been various attempts to soften it and make it easier to deform in order to improve weld amalgamation. The use of tungsten inert gas (TIG) welding and electrical resistance heating to achieve heat-assisted hybrid friction stir welding has been documented in the literature. The hybrid joining processes are found to be improving the joint's tensile properties.
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