Article
Nanoscience & Nanotechnology
Liting Shi, Jidong Kang, Cheng Qian, Jie Liang, Babak Shalchi-Amirkhiz, Amberlee S. Haselhuhn, Blair E. Carlson
Summary: A comparative study of resistance spot welded joints between 1.2 mm AA6022 and 2.0 mm high strength low alloy steel as well as 1.2 mm AA6022 and 2.0 mm low carbon steel revealed that the Fe2Al5 structure and properties at the Al-steel interface play a crucial role in determining the mechanical performance of the joint. Additionally, the different stack-ups resulted in variations in IMC strength and load capacity.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Nanoscience & Nanotechnology
Xiaopei Wang, Yoshiaki Morisada, Hidetoshi Fujii
Summary: A high-strength Fe/Al dissimilar joint was successfully fabricated using double-sided friction stir spot welding with adjustable probes, which introduced strong mechanical interlocks at the interface and a uniform IMC layer. The 30 nm IMC layer composed of a ternary phase of Al?Fe?Si, induced by fresh surface from the adjustable probes, resulted in a high-strength welded joint. This novel technique was effective and productive for joining dissimilar materials.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Materials Science, Multidisciplinary
Peizhi Xu, Xueming Hua, Chen Shen, Gang Mou, Fang Li
Summary: This study investigates the mechanism of silicon element in improving the joint strength of Al/steel dissimilar joints, showcasing that silicon helps enhance strength and suppress brittle fractures in the joint.
MATERIALS CHARACTERIZATION
(2021)
Article
Engineering, Mechanical
Lei Wang, Hongmei Li, Di Wu, Daqian Sun, Xinge Zhang
Summary: This study investigates the microstructures and fatigue behavior of dissimilar resistance spot welded joint between 5083 aluminum alloy and DP980 high strength steel, and finds that the fatigue load level affects the fracture mode.
FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES
(2022)
Article
Materials Science, Multidisciplinary
Qiaoling Chu, Lin Zhang, Tuo Xia, Peng Cheng, Jianming Zheng, Min Zhang, Jihong Li, Fuxue Yan, Cheng Yan
Summary: The microstructure and mechanical properties of the Fe-Nb dissimilar joint were investigated using nanoindentation, revealing variations in hardness and fracture toughness among different phases.
Article
Engineering, Manufacturing
Bo Pan, Hui Sun, Shun-Li Shang, Mihaela Banu, Pei-Chung Wang, Blair E. Carlson, Zi-Kui Liu, Jingjing Li
Summary: This research confirmed the formation mechanism of intermetallic compounds (IMCs) in Al/steel resistance spot welds and identified the formation of a rare AlFe structure. The study showed that Al13Fe4 first nucleates, followed by the growth of Al5Fe2 with Fe atoms accumulating at the Al13Fe4 grain boundaries. Coarse columnar grains of Al5Fe2 then form and AlFe forms at the interface of Al5Fe2 grains and the ferrite phase. Needle-like Al13Fe4 forms during the cooling process. In the middle and low welding energy regions, only limited Al5Fe2 and Al13Fe4 grains are formed at the interface or surrounded by the Al phase.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Materials Science, Multidisciplinary
Mingfeng Li, Wu Tao, Jiazhi Zhang, Yanjun Wang, Shanglu Yang
Summary: This work proposes an innovative hybrid resistance spot-laser welding process for joining aluminum to steel. The process first conducts resistance spot welding of aluminum and steel and then follows with laser spot welding. Through innovative electrode structure design, the welding current distribution and weld structure are optimized to achieve a thin and uniform intermetallic layer. The process also changes the faying interface morphology and improves the tensile-shear load and energy absorption of the joints.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
Mingfeng Li, Shanglu Yang, Yanjun Wang, Wu Tao
Summary: Reliably welding aluminum to steel is crucial in the automotive industry to achieve lightweight body structures. The proposed resistance spot welding process successfully joins AA6016 aluminum alloy and press hardened steel, forming an effective joint between the two materials.
Article
Materials Science, Multidisciplinary
Jiang Yu, Hongtao Zhang, Bo Wang, Chong Gao, Zhichao Sun, Peng He
Summary: Dissimilar metal joining between Q235 mild steel and TC4 titanium alloy was successfully achieved using resistance welding with interlayer, which resulted in welded joints with higher strength compared to conventional resistance spot welding. No apparent welding defects were observed in the welded joints.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Engineering, Manufacturing
Jian Liu, Biao Cao, Jingwei Yang
Summary: This study systematically investigated the microstructure and intermetallic compounds of Cu/Al joints produced by high power ultrasonic welding (HUSW). The research found that the welding time had little effect on the grain morphology and size of pure copper, but had a significant impact on the aluminum alloy. Moreover, the texture characteristics of copper and aluminum alloy also changed during the welding process.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Materials Science, Multidisciplinary
Vivek Kalyankar, Gautam Chudasama
Summary: A lightweight multi-material combination of steel and aluminium alloy is being used for environmentally sustainable transport systems. However, the joining of steel and aluminium is difficult due to the formation of brittle intermetallic compounds (IMC). This article reviews the challenges of IMC formation in steel/aluminium dissimilar resistance spot welding and summarizes the current methods to control IMC growth. Fe2Al5 is the most brittle and dominant IMC formed at the interface, but the application of a third-party interlayer can effectively reduce the growth and brittleness of IMC by changing its chemical configuration.
ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES
(2023)
Article
Materials Science, Multidisciplinary
Qing Jiang, Jin Yang, Rui Xiao, Min Zheng, Jiawei Jiang, Jing Xue, Wenhu Xu, Jiayi Xu, Hua Zhang
Summary: In this study, laser spot welding technology was used for the first time to join low carbon steel and AA5052 aluminum alloy using a FeCoNiCrMn equimolar high entropy alloys (HEAs) interlayer. The addition of the HEA interlayer promoted the formation of a Fe-rich Fe-Al IMC with reduced brittleness and hardness. As a result, the joint fracture load increased from 963 N to 1473 N and the displacement dramatically increased from 0.66 mm to 3.32 mm. Another contributing factor to the outstanding ductility of the dissimilar laser joint was the formation of a conical fusion zone, which enabled both metallurgical bonding and mechanical interlocking at the interface.
Article
Materials Science, Multidisciplinary
Luke Walker, Carolin Fink, Colleen Hilla, Ying Lu, Wei Zhang
Summary: There is an increased need to join magnesium alloys to high-strength steels to create multi-material lightweight body structures for fuel-efficient vehicles. Direct joining of these two metals is difficult, primarily because pure Mg and pure Fe are immiscible. Although a variety of interlayer materials have been used to facilitate the dissimilar joining in the literature, it is not well understood how the interlayer material affects the joint properties. In this study, a newly developed process, ultrasonic interlayered resistance spot welding (Ulti-RSW), was used to join an Mg alloy to a dual phase high-strength steel with two different interlayer materials: austenitic stainless steel and pure nickel. The IMCs formed with the two interlayers were drastically different, and computational thermodynamics and diffusion simulations revealed that such different IMCs resulted from the peculiar difference in nickel dissolution governed by local chemical potential gradients and diffusion kinetics. The joint with austenitic stainless steel inter layer had an under one micron thick Al-Fe IMC layer and a joint efficiency superior than that with the nickel interlayer as well as other joining processes in the literature.
MATERIALS & DESIGN
(2023)
Article
Materials Science, Multidisciplinary
Li Zhou, Shan Liu, Jie Min, Zhi-Wei Qin, Wen-Xiong He, Xiao-Guo Song, Hong-Bo Xu, Ji-Cai Feng
Summary: A good Al-Ti joint can only be achieved with proper welding energy, and no significant intermetallic compound (IMC) was found under all conditions. The heat input is crucial for material plastic flow and bonding area, playing an important role in joint formation.
INTERNATIONAL JOURNAL OF MINERALS METALLURGY AND MATERIALS
(2021)
Article
Materials Science, Multidisciplinary
Yue Yang, Zhen Luo, Yuanbo Bi, Yixuan Zhang
Summary: In order to achieve lightweight vehicles and energy-saving, the joining of dissimilar materials, specifically aluminum alloy and steel, has received increasing attention in car body structure. In this study, 6061 aluminum alloy and DP780 steel sheet were joined using resistance element welding (REW) technique with a flat Q235 rivet. The intermetallic compounds (IMCs) in the welded joints were analyzed using various characterization techniques, revealing the presence of Fe2Al5 and Fe4Al13 on the steel and aluminum sides, respectively.
MATERIALS CHARACTERIZATION
(2023)
Article
Optics
Masoud Mohammadpour, Nima Yazdian, Guang Yang, Hui-Ping Wang, Blair Carlson, Radovan Kovacevic
OPTICS AND LASER TECHNOLOGY
(2018)
Article
Engineering, Industrial
Nannan Chen, Hui-Ping Wang, Min Wang, Blair E. Carlson, David R. Sigler
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2019)
Article
Engineering, Industrial
Liting Shi, Jidong Kang, Babak Shalchi-Amirkhiz, David R. Sigler, Amberlee S. Haselhuhn, Blair E. Carlson
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2019)
Article
Engineering, Manufacturing
Can Chen, Liang Kong, Min Wang, Amberlee S. Haselhuhn, David R. Sigler, Hui-Ping Wang, Blair E. Carlson
JOURNAL OF MANUFACTURING PROCESSES
(2019)
Article
Optics
Chuanmin Zhu, Hailang Wan, Junying Min, Yu Mei, Jianping Lin, Blair E. Carlson, Surender Maddela
OPTICS AND LASERS IN ENGINEERING
(2019)
Article
Engineering, Electrical & Electronic
Yu-Jun Xia, Ze-Wei Su, Ming Lou, Yong-Bing Li, Blair E. Carlson
IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT
(2020)
Article
Engineering, Industrial
Zixuan Wan, Hui-Ping Wang, Jingjing Li, Joshua Solomon, Nannan Chen, Blair Carlson
Summary: This paper investigates the effect of beam oscillation frequency on spatter behavior in remote laser welding of thin-gauge zinc-coated steel. The experimental study shows that using a zigzag beam oscillation can improve weld aesthetics and reduce spatter-induced mass loss. Numerical simulations reveal that a suitable oscillation frequency leads to stable keyhole formation and reduced spatter.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)