Abstract
The 5052 aluminium alloy and 304 stainless steel were successfully joined by cutting-assisted welding-brazing (CAWB) method without using flux. Dual-scale interfacial structures were achieved by designing the geometry of cutting tool. Results indicated that the macroscale self-locking interface was produced when the taper step-shape cutting tool was adopted. Especially when the cutting tool step was increased to 6 steps, the microscale interface took on a micrometre-sized self-locking morphology and a layer of wavy intermetallic compound (IMC) with an average thickness of 3.3 μm was formed at the interface. The τ4 IMC particles and the FeAl6 phases on a small scale were dispersed homogeneously in the welded seam. The maximum tensile strength of the joints reached 152.3 MPa, 75% that of the 5052 aluminium base metal. The robust Al/steel dissimilar joints were attributed to the particle-reinforced weld metal and the macro- and microscale dual self-locking structure at the interface.
Highlights
In recent years, there has been an increasing interest on the part of academics in the integration of technologies with a lower thermal cycle [3]
One may expect that further improvement in bonding strength of Al/steel joint can be obtained if manipulating the cutting tool profile to achieve a unique combination of interfacial structure and strength
The aim of this study is to investigate the effect of two cutting tool types on the welding-brazing features of the joints
Summary
The light-weight alloy of Al/steel is increasingly attracting attention in the shipbuilding, aerospace and automotive industries [1]. There has been an increasing interest on the part of academics in the integration of technologies with a lower thermal cycle [3] Among these joining methods, the technology of welding-brazing aluminium alloy to steel with good flexibility has been increasingly considered [4]. Furuya et al [5] reported that the thickness of the IMC layer has been reduced by adding appropriate quantities of Si and Ti elements, and that the joint strength has been improved He et al [6] successfully joined aluminium and steel by pulsed TIG welding-brazing with high-frequency induction twin hot wire technology. The formation mechanisms of the joints were analysed to reveal the influence of cutting tool profiles and the joint microstructure on the tensile properties
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