Abstract
Joints between aluminum and galvanized steel pose a challenge for current manufacturing technologies. A hybrid joining method, which combines a pulsed and a continuous laser beam in a single process, has been identified as a potential solution for this challenge. The feasibility of this approach is verified by joining different base material alloys using zinc- and aluminum-based consumables. It is shown that the double beam method can be applied to different joint geometries by joining both double-flanged joints and lap joints. An analysis of the joint microstructure using metallographic cross-sections and transmission electron microscopy shows that intermetallic compounds can be limited to non-critical amounts. Tensile tests show that joint strengths in excess of 150MPa can be achieved for both types of joint geometries. When shear loads are applied, the use of aluminum-based consumables leads to superior strength.
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