Abstract
Austenitic and ferritic stainless-steel interlayers for resistance spot welding of an AlSi-coated 2000MPa UTS press-hardened boron steel and a 6022-T4 aluminium alloy were investigated to improve joint performance. CALPHAD and kinetic-based simulations were explored to determine the effects of Cr on the formation of Fe–Al intermetallic compounds. Selected area diffraction reveals the formation of FeCrAl9 along the interlayer-Al interface and suppresses the formation of FeAl3. The implementation of stainless-steel interlayers significantly improved the mechanical performance of the joint, with the 430 foil condition experiencing a substantial decrease in the Fe–Al intermetallic.
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