Abstract
In the last two decades, the automotive industry has been facing demands to reduce fuel consumption and to meet CO2 emissions through applications of lightweight materials. Therefore, aluminium alloys have replaced substantial amounts of steel; and they are receiving significant attention to achieve greenhouse emission targets. However, a critical factor in applications of advanced aluminium in automotive Body in White (BIW) designs depends on availability of cost effective and high performance joining processes. Currently, a Self-Pierce Riveting (SPR) process is extensively used for aluminium BIW sheet metal parts joining which is expensive, additionally increase the weight of the vehicle and cause inefficiency in manufacturing operations. As aluminium alloys are difficult to weld by conventional technologies such as electrical resistance spot welding, MIG arc welding etc., various joining technologies had proposed to weld aluminium alloys and dissimilar alloys over the years. Often, these technologies restrict design flexibility and are expensive for mass production. In this context, Remote Laser Welding (RLW) has gained popularity because of its distinct advantages such as design flexibility, production speed, material and cost savings. This paper provides a critical review of challenges and opportunities for application of RLW to dissimilar metal welding of steel to aluminium. Next steps of research and development are also highlighted.
Highlights
IntroductionSteel is widely used in automotive application because of its high tensile strength and low cost [1]
Steel and aluminium are most commonly used structural material
Remote Laser Welding (RLW) joining resulted in the formation of complex and heterogeneous microstructures composed of columnar grains and solute band (Fig. 1a to c)
Summary
Steel is widely used in automotive application because of its high tensile strength and low cost [1]. The advantages of AHSS is reduced BIW weight and enhance their crashworthiness [3]. Considering the stiffness required of each components, there is a certain limit to the reduction of weight with thinner AHSS sheets [2]. Aluminium (Al) have advantage over the steel because of its strength-toductility ratio, toughness and its inherent corrosion resistance with no need for an additional coating step [4]. Wrought Al alloys have advantages over overall body stiffness and impact energy absorption. It is unlikely that automobiles can ever be manufactured using only aluminium for applications. It becomes important to develop strategies and techniques, which can join dissimilar metals such as aluminium to steel [5]
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