Abstract
Laser conduction welding was used to directly join DH36 steel to AA5083 aluminium alloy in a T joint configuration, each plate with 6 mm of thickness. The effect of the process energy (via power density and interaction time) on the joint integrity and quality in terms of cracking, porosity and intermetallic compound layer formation was investigated. Successful T joints were produced by melting of the aluminium plate, which was inserted into a 4 mm deep groove machined on the steel plate, with the heat generated by the laser irradiation on the steel surface. The IMC layer thickness was less than 5 μm. Although cracking was observed along the IMC layer with higher levels of energies, the joints were still strong due to the mechanical inter-locking effect resulting from the novel design of the component, whereby the IMCs were subjected to compressive state of stress while loading.
Highlights
The research in dissimilar metal joining of steel to aluminium is mainly focused on thin gauge materials for applications in automotive industry
The results presented refer to the cross-sections of the T joints
Laser conduction welding of steel to aluminium has successfully been transferred from the lap joint configuration to the T joint configuration
Summary
The research in dissimilar metal joining of steel to aluminium is mainly focused on thin gauge materials for applications in automotive industry. This bar permits joining of steel substrate to the steel side and the aluminium substrate to the aluminium side by fusion welding the component Even though this design solution overcomes the loss in strength by avoiding formation of intermetallic compounds (IMCs), there are a few disadvantages. By controlling the relative position of the heat source in relation to the joint interface and adding filler metal it is possible to avoid melting of the substrate, minimize the reaction between the Fe and Al and create less IMCs. Successful lap-welded joints of 1.2 mm thick hot-dip aluminized (Alcoated) steel to 1.0 mm thick AA5052 aluminium alloy were produced using this technique and a variant of GMAW process, called cold metal transfer (CMT). The effect of the process energy, via power density and interaction time, on the joint integrity and quality in terms of cracking, porosity and IMC layer formation was investigated
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