Application of ultrasonic vibrations in welding and metal processing: A status review

Microstructure and mechanical properties of dissimilar Al alloy/steel joints prepared by a flat spot friction stir welding technique

Hydrogen related degradation in pipeline steel: A review

Effect of ultrasonic welding parameters on microstructure and mechanical properties of dissimilar joints

Joining aluminum to steel can lighten the weight of components in the automobile and other industries, which can reduce fuel consumption and harmful gas emissions to protect the environment. However, the differences of thermal, physical, and chemical properties between aluminum and steel bring a series of problems in laser welding. The main problems are how to control the thickness of the intermetallic compound layer and reduce or avoid the generation of pores, cracks, and thermal stresses which severely limit the mechanical properties of welded joints. Laser fusion-brazing technology utilizes the precise control of heat input with or without filler to partially melt the low melting temperature aluminum base material and promote wetting on the high melting temperature steel base material in order to achieve sound metallurgical by combining the advantages of fusion welding and brazing. Different forms of laser beam welding including single beam laser welding, dual-beam laser welding, and laser arc hybrid fusion-brazing welding are reviewed.

Laser welding dissimilar materials of aluminum to steel: an overview

Energy efficient methods for joining aluminium to steel have potential for major applications in the automobile industry. Results are reported where 1 mm gauge 6111 aluminium and DC04 steel automot...

Ultrasonic spot welding of aluminium to steel for automotive applications—microstructure and optimisation

Rapid intermetallic growth under high strain rate deformation during high power ultrasonic spot welding of aluminium to steel

Microstructural and mechanical performance of aluminium to steel high power ultrasonic spot welding

Dissimilar joining of aluminum to steel sheet in multimaterial automotive structures is an important potential application of ultrasonic spot welding (USW). Here, the weldability of different zinc-coated steels with aluminum is discussed, using a 2.5-kW USW welder. Results show that soft hot-dipped zinc (DX56-Z)-coated steel results in better weld performance than hard (galv-annealed) zinc coatings (DX53-ZF). For Al to hard galv-annealed-coated steel welds, lap shear strengths reached a maximum of ~80% of the strength of an Al-Al joint after a 1.0 s welding time. In comparison, welds between Al6111-T4 and hot dipped soft zinc-coated steel took longer to achieve the same maximum strength, but nearly matched the Al-Al joint properties. The reasons for these different behaviors are discussed in terms of the interfacial reactions between the weld members.

Farid Haddadi

Papers

Ultrasonic spot welding of aluminium to steel for automotive applications—microstructure and optimisation

Rapid intermetallic growth under high strain rate deformation during high power ultrasonic spot welding of aluminium to steel

Microstructural and mechanical performance of aluminium to steel high power ultrasonic spot welding

Effect of zinc coatings on joint properties and interfacial reactions in aluminum to steel ultrasonic spot welding

Grain structure, texture and mechanical property evolution of automotive aluminium sheet during high power ultrasonic welding