Emerging trends in manufacturing such as light weighting, increased performance and functionality increases the use of multi-material, hybrid structures and thus the need for joining of dissimilar materials. The properties of the different materials are jointly utilised to achieve product performance. The joining processes can, on the other hand be challenging due to the same different properties. This paper reviews and summarizes state of the art research in joining dissimilar materials. Current and emerging joining technologies are reviewed according to the mechanisms of joint formation, i.e.; mechanical, chemical, thermal, or hybrid processes. Methods for process selection are described and future challenges for research on joining dissimilar materials are summarized.

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Joining of dissimilar materials

Iron (Fe) and its counterparts, such as Fe2O3, Fe3O4, carbonyl iron and FeO, have attracted the attention of researchers during the past few years due to their bio-compatibility, bio-degradability and diverse applications in the field of medicines, electronics and energy; including water treatment, catalysis and electromagnetic wave interference shielding etc. In this review paper, we aimed to explore iron based materials for the prevention of electromagnetic interference (EMI) by means of both reflection and absorption processes, including the standard methods of synthesis of Fe-based materials along with the determination of EMI performance. It is customary that a proper combination of two dielectric-losses, i.e. electrical and magnetic losses, give excellent microwave absorption properties. Therefore, we focused on the different strategies of preparation of these iron based composites with dielectric carbon materials, polymers etc. Additionally, we explained their positive and negative aspects.

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Review of electromagnetic interference shielding materials fabricated by iron ingredients

Comparative study of the application of steels and aluminium in lightweight production of automotive parts

Welding of dissimilar magnesium alloys and aluminum alloys is an important issue because of their increasing applications in industries. In this document, the research and progress of a variety of welding techniques for joining dissimilar Mg alloys and Al alloys are reviewed from different perspectives. Welding of dissimilar Mg and Al is challenging due to the formation of brittle intermetallic compound (IMC) such as Mg17Al12 and Mg2Al3. In order to increase the joint strength, three main research approaches were used to eliminate or reduce the Mg-Al intermetallic reaction layer. First, solid state welding techniques which have a low welding temperature were used to reduce the IMCs. Second, IMC variety and distribution were controlled to avoid the degradation of the joining strength in fusion welding. Third, techniques which have relatively controllable reaction time and energy were used to eliminate the IMCs. Some important processing parameters and their effects on weld quality are discussed, and the microstructure and metallurgical reaction are described. Mechanical properties of welds such as hardness, tensile, shear and fatigue strength are discussed. The aim of the report is to review the recent progress in the welding of dissimilar Mg and Al to provide a basis for follow-up research.

A Review of Dissimilar Welding Techniques for Magnesium Alloys to Aluminum Alloys.

Microstructure and mechanical properties of 6061 Al alloy based composites with SiC nanoparticles

The effects of the welding current on heat input, nugget geometry, and the mechanical and fractural properties of resistance spot welding on Mg/Al dissimilar materials

An effect of heat input, weld atmosphere and weld cooling conditions on the resistance spot weldability of 316L austenitic stainless steel

Zinc coated dual phase 600 steel (DP 600 grade) was investigated, utilisation of which has gradually increased with each passing day in the automotive industry. The adhesive bonding (AB), resistance spot welding (RSW), and adhesive weld bonding (AWB) joints of the zinc coated DP 600 steel were investigated. Additionally, the zinc coating was removed using HCL acid in order to investigate the effect of the coating. The microstructure, tensile shear strengths, and fracture properties of adhesive bonding (AB), resistance spot welding (RSW), and adhesive weld bonding (AWB) joints of the coated and uncoated DP 600 steel were compared. In addition, a mechanical-electrical-thermal coupled model in a finite element analysis environment was utilised. The thermal profile phenomenon was calculated by simulating this process. The results of the tensile shear test indicated that the tensile load bearing capacity (TLBC) values of the coated specimens among the three welding methods were higher than those of the uncoated specimens. Additionally, the tensile strength of the AWB joints of the coated and uncoated specimens was higher than that of the AB and RSW joints. It was determined that the fracture behaviours and the deformation caused were different for the three welding methods.

Comparing Properties of Adhesive Bonding, Resistance Spot Welding, and Adhesive Weld Bonding of Coated and Uncoated DP 600 Steel

Grade A (GA) and high strength steel DH36 ship steels possessing different chemical compositions were used, and strength properties of GA steel and DH36 steel were compared. Additionally, 4 types of dual phase (DP) steels with different martensite volume fractions (MVFs) were produced from GA steel by means of heat treatment and they were compared with other steels through conducting microstructure, microhardness, tensile and impact tests. The fracture surfaces of specimens (DH36, GA and DP steels) exposed to tensile and Charpy impact tests were investigated by scanning electron microscope. Furthermore, it was found that the specimens quenched from 800 and 900 °C had better strength than DH36 steel. The tensile test results indicated that the tensile strength of DP steel water quenched from 900 °C was 3 times that of GA steel and twice that of DH36 steel.

Effect of Heat Treatment on Microstructure, Mechanical Properties and Fracture Behaviour of Ship and Dual Phase Steels

The similar and dissimilar resistance spot weldability of 6061-T6 and 7075-T651 aluminium alloys was investigated in this study. Resistance spot weldability of commercial and aged samples in different variations was examined. The microstructure, microhardness, scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD) and electron probe micro-analyses (EPMA) were conducted to study the effects aging heat treatment had on similar and dissimilar resistance spot welded (RSW) joints. In addition, tensile shear tests were performed to determine the mechanical properties and fracture behaviour of welded joints. The tests concluded that pre-weld aging heat treatment improves mechanical properties.

Fatih Hayat

Papers

The effects of the welding current on heat input, nugget geometry, and the mechanical and fractural properties of resistance spot welding on Mg/Al dissimilar materials

An effect of heat input, weld atmosphere and weld cooling conditions on the resistance spot weldability of 316L austenitic stainless steel

Comparing Properties of Adhesive Bonding, Resistance Spot Welding, and Adhesive Weld Bonding of Coated and Uncoated DP 600 Steel

Effect of Heat Treatment on Microstructure, Mechanical Properties and Fracture Behaviour of Ship and Dual Phase Steels

Effect of aging treatment on the microstructure and mechanical properties of the similar and dissimilar 6061-T6/7075-T651 RSW joints