Abstract
Cold welding, e.g. by cold forging, is a smart manufacturing technology, enabling novel multi material designs. A material combination, which is particularly attractive for manufacturing, though challenging to handle in a cold welding process, is steel and aluminum. We investigate the bond formation between cold forged C 15 (mainly primary heat treated) and AW 6082. Analysis starts with numerical simulations using the finite element analysis (FEA) to identify optimum conditions for bond formation. The bond strength was determined by tensile tests from samples eroded from the cold-welded specimen. Best performing samples showed a maximum tensile strength of ~200 MPa with ductile failure in the AW 6082. Transmission electron microscopy (TEM) inspection of the bonded area between aluminum and steel show a reaction layer consisting of iron and aluminum of few nm thickness throughout the sample. The formation of such a reaction layer is hypothesized to be crucial for bond formation.
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