Abstract
The tungsten inert gas (TIG) welding method most commonly used to weld ferrous metals, nonferrous metals, and other metals since it is simple, easily implemented, and achieves consistent high-quality welds. In this study, butt joints produced between aluminum alloy A6061-T6 and stainless steel SUS304L have been achieved by using TIG welding with ER4047 filler metal. The macrostructure and microstructure of the resulting specimens were analyzed by means of an optical microscope (OM), a scanning electron microscope (SEM), and an energy dispersive X-ray spectrometer (EDS). A uniform intermetallic layer was found at the interface between the stainless steel and the weld seam having a thickness of 2 µm, and the intermetallic compound (IMC) includes Fe4Al13, Fe2Al5, and FeAl3 phases. The micro-hardness and tensile strength of the weld joints were also investigated. Due to Si content in the compensating metal, there was a prevention of iron diffusion into the aluminum, thus hindering the development of the IMC layer and reducing its thickness in such a way that the weld joint strength increases. The analyzed results show that the average micro-hardness of the stainless steel, weld seam, aluminum alloys, and IMC layer were 218 HV, 88.3 HV, 63.3 HV, and 411 HV, respectively. The fracture occurred at the brazed interface, and the ultimate tensile strength value reached 225 MPa.
Highlights
In order to improve diverse product attributes such as product quality, weight reduction, cost reduction and savings, and decreased environmental pollution during the industrial welding applications, a hybrid structure of dissimilar metals including Al/Mg, Al/Cu, Al/Ti, Al/Al, Ti alloy/Fe alloy, Mg/Fe [1,2,3,4,5,6,7,8] has been adopted for industrial usage
In order to ameliorate this circumstance, many different welding methods have been utilized for the welding of aluminum alloys and stainless steel, including friction stir welding [4,12], metal inert gas welding [13,14,15,16,17], laser welding [5,18,19,20,21], resistance sport welding [22], Materials 2018, 11, 1136; doi:10.3390/ma11071136
Lin et al [27] found two intermetallic phases which formed at the interface between the weld seam and the steel, with the weld side having a phase of τ5 –Al7 Fe2 Si, and the stainless steel side having a phase of θ-FeAl3
Summary
In order to improve diverse product attributes such as product quality, weight reduction, cost reduction and savings, and decreased environmental pollution during the industrial welding applications, a hybrid structure of dissimilar metals including Al/Mg, Al/Cu, Al/Ti, Al/Al, Ti alloy/Fe alloy, Mg/Fe [1,2,3,4,5,6,7,8] has been adopted for industrial usage. Lin et al [26] investigated the microstructure and mechanical properties of butt joining-brazing between 5A06 aluminum alloy and SUS 321 stainless steel by using TIG welding with Al-Cu6 filler metal non-corrosive flux These researchers found that the IMC layer appeared at the interface between the weld seam and the steel side, with a thickness of 3–5 μm. Lin et al [27] found two intermetallic phases which formed at the interface between the weld seam and the steel, with the weld side having a phase of τ5 –Al7 Fe2 Si, and the stainless steel side having a phase of θ-FeAl3 When these researchers studied the metallurgical and mechanical properties of dissimilar tungsten inert gas-welded butt joints between aluminum alloy 5A06 to stainless steel SUS 321 utilizing BJ380A filler wire and modified non-corrosive flux. A6061-T6 alloy and SUS304L steel butt joints were successfully produced by means of a pulse tungsten inert gas (TIG) welding-brazing process, and the microstructural and mechanical properties of the weld joint were discussed
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