Abstract
In order to improve the joining performance between aluminum alloy and steel, a method termed resistance projection-plug welding was tried to weld steel to aluminum alloy. The microstructure and properties of the joint obtained by this method under various welding parameters were analyzed. Scanning electron microscopy studies of the interfacial microstructures revealed that a reaction layer, consisting of Fe2Al5 adjacent to steel and FeAl3 adjacent to aluminum alloy, is formed in the interface outside the nugget. The maximum tensile shear and cross-tension loads of the joint reached 6.92 and 4.13 kN, respectively, in comparison with 5.0 and 1.4 kN, respectively, for resistance spot welding with a cover plate. The results revealed that the resistance projection-plug welding is an effective method for welding steel and aluminum alloys.
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