Abstract
The intermetallic layer, which forms at the bonding interface in dissimilar welding of aluminum alloys to steel, is the most important characteristic feature influencing the mechanical properties of the joint. In this work, horizontal butt-welding of thin sheets of aluminum alloy EN AW-6014 T4 and galvanized mild steel DC04 was investigated. In order to predict the thickness of the intermetallic layer based on the main welding process parameters, a numerical model was created using the software package Visual-Environment. This model was validated with cold metal transfer (CMT) welding experiments. Based on the calculated temperature field inside the joint, the evolution of the intermetallic layer was numerically estimated using the software Matlab. The results of these calculations were confirmed by metallographic investigations using an optical microscope, which revealed spatial thickness variations of the intermetallic layer along the bonding interface.
Highlights
Dissimilar joining of aluminum alloy sheets to steel sheets is an indispensable key process for producing multimaterial car bodies, offering both high crash safety and low vehicle weight
Fusion welding processes in particular have marked advantages regarding the efficient joining of hybrid parts of complex shapes
Thermal joining of aluminum- (Al) to iron- (Fe) based materials is known to be associated with the formation of intermetallic (IM) Alx Fey phases at the bonding interface [1,2,3]
Summary
Dissimilar joining of aluminum alloy sheets to steel sheets is an indispensable key process for producing multimaterial car bodies, offering both high crash safety and low vehicle weight. Thermal joining of aluminum- (Al) to iron- (Fe) based materials is known to be associated with the formation of intermetallic (IM) Alx Fey phases at the bonding interface [1,2,3]. The formation of these phases is mandatory for bonding of the dissimilar materials, excessive formation results in brittleness and in poor mechanical properties of the joints. Bouayad et al [17] observed that growth of the Al5 Fe2
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