Abstract
Summary This paper describes an investigation of the dissimilar metal spot welding of aluminium and steel sheet with an aluminium clad steel sheet insert. The study relates to application of this system in automotive fabrication in an effort to reduce motor vehicle weight. To ascertain the mechanical properties of the intermetallic compounds formed at the steel and aluminium bond interface, measurements were performed using four types of Fe‐Al binary system intermetallic compound. The mechanical properties of spot‐welded joints in aluminium and steel sheet with and without insertion of an aluminium clad steel sheet were measured by the cross tension test, and the microstructures of the welded joints then formed were observed. The intermetallic compounds FeAl and Fe3Al have a relatively high ductility, and Fe2Al5 and FeAl3 have a high hardness and low ductility. Fe2Al5 intermetallic compounds were formed in the spot‐welded zones of the aluminium and steel sheet, resulting in loss of strength. The dissimila...
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