Abstract
Butt joints of A5052 aluminum alloy and SS400 steel, with a new type of chamfered edge, are welded by means of metal inert gas welding and ER4043 Al-Si filler metal. The microhardness and microstructure of the joint are investigated. An intermetallic layer is found on the surface of the welding seam and SS400 steel sheet. The hardness of the intermetallic layer is examined using the Vickers hardness test. The average hardness values at the Intermetallic (IMC) layer zone and without the IMC layer zone were higher than that of the welding wire ER4043. The tensile strength test showed a fracture at the intermetallic layer when the tensile strength is 225.9 MPa. The tensile value test indicated the average of welds was equivalent to the 85% tensile strength of the A5052 aluminum alloy. The thickness of the intermetallic layers is non-uniform at different positions with the ranges from 1.95 to 5 μm. The quality of the butt joint is better if the intermetallic layer is minimized. The Si crystals which appeared at the welding seam, indicating that this element participated actively during the welding process, also contributed to the IMC layer’s formation.
Highlights
Aluminum alloys are widely applied in the shipbuilding, aerospace, and automotive industries, as well as many other areas, because of their numerous advantages [1,2]
Butt joint research is important because it deals with the complex problems of the welding process in the heat-affected zone (HAZ), the bearing capacity and the reduction in quality due to the stress and distortion that always exist after welding
The four elements and corresponding amounts were Al (45.9%), Fe (30.2%), Figure 9 shows the results of the Energydispersive dispersive X-ray spectrometer spectrometer (EDS) analysis between the welding seam and SS400 steel interface layer obtained in line scanning mode
Summary
Aluminum alloys are widely applied in the shipbuilding, aerospace, and automotive industries, as well as many other areas, because of their numerous advantages [1,2]. Steel is used mostly in the manufacturing industry and in steel structures [3,4] Combining these two materials can reduce both the time and cost of manufacturing, but it has been found that diffusion at the welds negatively affects weld quality. Various methods have been used to achieve optimal results when welding aluminum alloys and steel, such as friction stir welding [5,6], laser welding [2,7], resistance spot welding [8,9], and ultrasonic welding [10,11]. The heat source causes highly non-uniform temperature distributions across the welding seam and the base metals. This welding process has five types of joints commonly used in industrial applications: butt, tee, corner, lap, and edge. Butt joint research is important because it deals with the complex problems of the welding process in the heat-affected zone (HAZ), the bearing capacity and the reduction in quality due to the stress and distortion that always exist after welding
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