Abstract

Galvanized dual-phase steel sheets are extensively used by the auto industry for their corrosion resistance property. Welding by the metal inert gas (MIG) process causes degradation of the steel in the vicinity of the joint due to excessive zinc evaporation. In order to minimize Zn loss, the MIG brazing process has been tried out in lap joint configuration over a heat input range of 136–204 J mm−1. The amount of zinc loss, intermetallic formation and corrosion properties in the joint area has been evaluated for both MIG brazing and MIG welding. Corrosion rate of 21 mm year−1 has been reduced to 2 mm year−1 by adopting MIGB in place MIGW. Impedance study has shown that the corrosion mechanism in base metal, MIG brazed and MIG welded joints is dominated by charge transfer, diffusion and mixed mode control processes, respectively.

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