Laser techniques for dissimilar joining of aluminum alloys to steels: A critical review

Microcracks initiated and propagated behaviors in Al/steel interface determined interfacial bonding strength and this was observed by in situ scanning electron microscopy (SEM) technology. Interface without or with discontinuous intermetallic compound (IMC) had low bonding strength owing to insufficient metallurgical bonding. When interface was joined with 2–3 μm serration–shaped τ5–Fe1.8Al7.2Si, largest bonding strength of 205 MPa was obtained. Microcracks initiated at protrusion of τ5–Fe1.8Al7.2Si and then propagated to τ5–Fe1.8Al7.2Si layer and τ5–Fe1.8Al7.2Si/Al interface. When interface was joined with 3–5 μm θ–Fe(Al,Si)3 + τ5–Fe1.8Al7.2Si, microcracks initiated at root of IMC layers and the interfacial bonding strength was 150 MPa. When interface was joined with 5–10 μm θ–Fe(Al,Si)3 + τ5–Fe1.8Al7.2Si, microcracks initiated and propagated along IMC layer. Lower interfacial bonding strength (106 MPa) was produced owing to large lattice mismatch between θ–Fe(Al,Si)3 and τ5–Fe1.8Al7.2Si, microdefects and higher residual stress. When interface was joined with 10 μm η–Fe2(Al,Si)5 + θ–Fe(Al,Si)3 + τ5–Fe1.8Al7.2Si, microcracks initiated and propagated along η–Fe2(Al,Si)5 layer or steel/η–Fe2(Al,Si)5 interface. Lowest bonding strength (64 MPa) was obtained resulted from pre–generated microcracks in η–Fe2(Al,Si)5 layer, largest residual stress, crystal defects and abnormal aggregation of Si. 

In situ SEM study on tensile fractured behavior of Al/steel laser welding-brazing interface

In the present study, the effect of process parameters in Wire Arc Additive Manufacturing (WAAM) of Stainless Steel 304 as filler wire and mild steel as a substrate has been investigated. The depos...

Parameters effect on SS304 beads deposited by wire arc additive manufacturing

The effect of laser, Hybrid Laser-Tungsten inert gas (HLT) and Hybrid Laser-Metal inert gas (HLM) welding processes on the microstructure and mechanical properties of 5.6 mm thick 316L(N) stainless...

Laser and hybrid laser welding of type 316L(N) austenitic stainless steel plates

Maraging steel 250 grade plates of 10 mm thickness were welded in single pass using a laser-arc hybrid welding (LHW) setup comprising 3.5 kW CO2 laser and synergic pulse metal inert gas (MIG) welding power source at a welding speed of 1 m/min. The influence of single-pass welding on the bead characteristics, microstructure, and mechanical properties was investigated. The size and volume fraction of reverted austenite was effectively reduced in the fusion zone. Moreover, the width of the heat-affected zones (HAZ) was reduced and the microhardness results did not show significant softening in the HAZ after post weld aging. Tensile testing of the welds in transverse direction showed 97.3% weld efficiency. The fusion zone exhibited KIc fracture toughness of 77.4 MPa√m which was affected by the distribution pattern of reverted austenite. The study vividly brings out the process advantages of LHW for accomplishing thick section welds of maraging steel in single pass with narrow groove and lesser filler wire con...

Single Pass Laser-Arc Hybrid Welding of Maraging Steel Thick Sections

Integrity of 5052 Al-mild steel dissimilar welds fabricated using MIG-brazing and cold metal transfer in nitric acid medium

Lap welds of 19000 Al–Zinc layered mild steel were joined by Cold Metal Transfer technique using Al-12% Si filler wire as a function of varying weld speed (0.5–1 m.min−1). The weld cross-se...

Effect of varying weld speed on corrosion resistance and mechanical behavior of Aluminium - steel welds fabricated by cold metal transfer technique

Partial replacement of steel by Aluminium (Al) alloys is a promising approach adopted by automotive sector to improve fuel efficiency without compromising on the strength. However, this results in the generation of dissimilar welds of Al alloys and steel. Understanding the corrosion behavior of Al alloys–steel welds as a function of welding parameters is critical in the successful application of such alloys. The present study reports the intergranular corrosion behavior of T6 heat-treated AA6061 Al alloy-galvanized mild steel lap joints, welded by metal inert gas welding–brazing technique as a function of different welding parameters, viz. weld speed (4-6 m/min) and wire feed rate (0.8-0.9 m/min), following ASTM G 67-04. Weld characterization was performed by field emission scanning electron microscopy (FESEM), x-ray diffraction and nano-hardness measurement. Results indicate heavy dissolution and metal loss at the interface. A high volume fraction of Al-Fe intermetallics was precipitated at the weld interfaces, resulting in high hardness and higher localized corrosion. The thickness of Al-Fe intermetallic layer increased with increasing wire feed rate and lower weld speed which enhanced the severity of galvanic and intergranular corrosion.

K. V. Phani Prabhakar

Papers

Single Pass Laser-Arc Hybrid Welding of Maraging Steel Thick Sections

Integrity of 5052 Al-mild steel dissimilar welds fabricated using MIG-brazing and cold metal transfer in nitric acid medium

Effect of varying weld speed on corrosion resistance and mechanical behavior of Aluminium - steel welds fabricated by cold metal transfer technique

Effect of Welding Parameters on the Corrosion Behavior of Dissimilar Alloy Welds of T6 AA6061 Al-Galvanized Mild Steel

Structure-property evaluation of single pass Laser-arc hybrid welding of re-sulphurized martensitic stainless steel