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Abstract
Plasma arc welding of dissimilar DP1180 ultrahigh-strength steel and 5A06 aluminum alloy assisted by copper transition layer was applied and a hybrid joint was obtained consisting of two metallurgical bonding zones. The hybrid joint consisted of the weld formed by the fusion welding of steel and copper on steel side, unmelted Cu and the Cu-Al interface layer formed by liquid phase diffusion reaction. The unmelted Cu acted as a diffusion barrier between steel and Al-alloy, and no Fe-Al intermetallics were detected in the weld. The Cu-Al interface layer composed of Cu9Al4 + CuAl2 + CuAl2/α-Al eutectic and the formation mechanism of the Cu-Al interface layer was discussed. Mechanical testing of the hybrid joints revealed that the average tensile strength was 125 MPa and all the tensile samples fractured at Cu-Al interface layer containing Cu9Al4 and CuAl2.
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