Abstract
The mechanism of the interface layer formation between steel and aluminum dissimilar materials is unclear by now. An interfacial bonding was investigated by joining steel sheets to 6061 aluminum sheets under a thermal and mechanical coupled loading. The effects of temperature and zinc coating on microstructural evolution and shear strength of the interface layer were both studied. The experimental results showed that the interface layer between the uncoated steel and aluminum was mainly composed of FeAl3 intermetallic compound (IMC). The shear strength of the joint increased with temperature. The existence of the zinc coating was able to lower the temperature to form the interface layer and improve its shear strength. The interface layer between the zinc coated steel and aluminum was mainly composed of Fe2Al5Znx and Al-Zn eutectic phases with a lower micro hardness. That suggested that the brittleness of the interface layer composed of the Fe-Al IMC could be avoided by modify the zinc coating and temperature. A zinc foil was added between steel and aluminum sheets to amplify the interface layer for microstructure observation. Based on the results an interface bonding model of steel and aluminum dissimilar materials considering the temperature and zinc coating was proposed.
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