Laser Welding of UNS S33207 Hyper-Duplex Stainless Steel to 6061 Aluminum Alloy Using High Entropy Alloy as a Filler Material

Dhanesh G Mohan,Jacek Tomków,Sasan Sattarpanah Karganroudi

doi:10.3390/app12062849

Abstract

The high entropy alloy (HEA) filler used during the fabrication method determines the reliability of HEAs for steel-aluminum dissimilar alloy configuration. HEAs have a direct impact on the formation of intermetallic compounds (IMC) formed by the interaction of iron (Fe) and aluminum (Al), and influence the size of the joint’s interaction zone. A novel welding process for Fe-Al alloy joints was developed to prevent the development of a brittle iron-aluminum interface. This research involved investigation of the possibility of using HEA powdered filler. Fe5Co20Ni20Mn35Cu20 HEAs was used as a filler for the laser joining lap configuration joining hyper-duplex stainless steel UNS S33207 to aluminum alloy 6061. This HEA has unique properties, such as high strength, good ductility, and high resistance to corrosion and wear. A tiny portion of the stainless-steel area was melted by varying the welding parameters. The high-entropy alloy (HEA) with slow kinetic diffusion and large entropy was employed to aid in producing solid solution structures, impeding the blending of iron and aluminum particles and hindering the development of Fe-Al IMCs. The weld seam was created without the use of Fe-Al IMCs,. The specimen broke at the HEAs/Al alloy interface with a tensile-shear strength of 237 MPa. The tensile-shear strength achieved was 12.86% higher than for the base metal AA 6061 and 75.57% lower than for the UNS S33207 hyper-duplex stainless steel.

Highlights

A hybrid joint made of dissimilar metals has been a focus of research in battery case manufacturing, and in the automotive and marine sectors for a long time [1,2]
The results showed that the average microhardness achieved in the weld zone where high entropy alloy (HEA) filler was deposited was 674 HV
It is well established that intermetallic compound layer thickness, phase transformations and area of bonding have an overriding influence on the mechanical and metallurgical properties of welding using stainless steel and aluminum alloys

Summary

Introduction

A hybrid joint made of dissimilar metals has been a focus of research in battery case manufacturing, and in the automotive and marine sectors for a long time [1,2]. As the presence of these IMCs limits the strength of the joint, the amount of these compounds should be kept to a minimum. All fusion welding methods occur in transient conditions, and the time and temperature cannot be separately controlled. The heat cycle applied to the weldment determines the thickness of the IMC layer and the width of the weld [5,6]. To regulate these two components, it is first necessary to understand the heat cycle and its effects

Methods

Results

Conclusion