Abstract
Formation of porosity and intermetallic compounds (IMCs) were studied in electron beam welded (EBW) DP-600 steel to Al-5754 alloy joints at three different weld conditions such as without beam oscillation, with beam oscillation and with varying beam oscillation diameter. X-ray Diffraction (XRD), scanning electron microscopy (SEM), microhardness, three-dimensional X-ray computed tomography (XCT) were used to characterize porosity and IMCs distribution in these weld joints. Beam oscillation with optimum oscillation diameter (1 mm diameter) improved the weld quality by reducing the amount, maximum size and porosity contents in weld zone significantly. For IMCs, average size increased little bit but maximum size, percentage of formation and amount reduced. By increasing oscillation diameter (2 mm diameter) beyond optimum value (1 mm diameter), quality of joints was found to deteriorate with accompanying higher porosity content, average pore size, average IMCs size etc. Raman spectroscopy and gas analyzer were also used to identify and quantify the entrapped gases in the weld joint.
Highlights
Automotive industries have some basic agendas like reduction of vehicle exhaust emissions, improvement of occupant safety, energy saving and anti-pollution laws
We report the characterization of porosity and intermetallic compounds (IMCs) formation in EB-welded DP steel to Al alloys dissimilar joints for different weld conditions
It is further observed that different IMCs such as FeAl, FeAl2, FeAl3, FeAl6, Fe2Al5, Fe4Al13 were characterized by smaller peaks and mostly overlapping with the base metal peaks
Summary
Automotive industries have some basic agendas like reduction of vehicle exhaust emissions, improvement of occupant safety, energy saving and anti-pollution laws. Such requirements lead to the development of the materials like high strength steels, aluminium alloys, plastics and carbon fiber reinforced plastics. Mohandas et al (1999) reported that the presence of porosities, microcracks, and IMCs in electron beam welding . These types of weld defects were characterized by conventional methods like ultrasonic, radiography, optical, SEM, EDS, etc. With the aid of X-ray computed tomography (XCT), it is possible to study different types of weld defects in three dimensions
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