The modified Zn interlayer was introduced to realise the tungsten inert gas (TIG) arc lap welding of DP780 steel (upper plate) and 6061 aluminum alloy (lower plate). The tensile shear force of the joint could be increased to more than 150 N/mm by introducing a modified Zn interlayer with a large hole diameter and hole spacing. The large hole diameter and spacing can regulate the heat conduction effect of the steel–aluminum interface, increase the welding penetration and width of the aluminum side and facilitate adequate metallurgical reactions. Moreover, allowing a certain amount of Zn vapour to escape promptly is beneficial, ensuring the stability of the interfacial melting pool and achieving high-quality welded joints.
TaubAILuoAA. Advanced lightweight materials and manufacturing processes for automotive applications. MRS Bull2015; 40: 1045–1054.
2.
HirschJAl-SammanT. Superior light metals by texture engineering: optimized aluminum and magnesium alloys for automotive applications. Acta Mater2013; 61: 818–843.
3.
ZhouZGaoXZhangY. Research progress on characterization and regulation of forming quality in laser joining of metal and polymer, and development trends of lightweight automotive applications. Metals2022; 12: 1666.
4.
Echaniz HernándezE. Development of aluminim/steel hybrid structures by semisolid forming. 2016. doi:10.48764/c5s4-ds41
5.
LiYYangDYangW, et al.Multiphysics numerical simulation of the transient forming mechanism of magnetic pulse welding. Metals2022; 12: 1149.
6.
LeeKJKumaiSKawamuraN, et al.Growth manner of intermetallic compounds at the weld interface of steel/aluminum alloy lap joint fabricated by a defocused laser beam. Mater Trans2007; 48: 1396–1405.
7.
WangJFuXZhangL, et al.A short review on laser welding/brazing of aluminum alloy to steel. Int J Adv Manuf Technol2021; 112: 2399–2411.
8.
LiRYuanXZhangH, et al.Effect of axial magnetic field on TIG welding–brazing of AA6061 aluminum alloy to HSLA350 steel. J Mater Res Technol2021; 12: 882–893.
9.
ShafferDGrimmTJRagaiI, et al.Utilization of XSYTIN-1 tool in electrically-assisted friction stir welding of dissimilar metals-Al 6061-T651 to mild steel. Adv Mater Res2019; 1152: 31–41.
10.
LiuJHaoZXieY, et al.Interface stability and fracture mechanism of al/steel friction stir lap joints by novel designed tool. J Mater Process Technol2022; 300: 117425.
11.
ElangoESaravananSRaghukandanK. Experimental and numerical studies on aluminum-stainless steel explosive cladding. J Cent South Univ2020; 27: 1742–1753.
12.
ShiHQiaoSQiuR, et al.Effect of welding time on the joining phenomena of diffusion welded joint between aluminum alloy and stainless steel. J Manuf Process2012; 27: 1366–1369.
13.
WuKYuanXLiT, et al.Effect of ultrasonic vibration on TIG welding–brazing joining of aluminum alloy to steel. J Mater Process Technol2019; 266: 230–238.
14.
XiaHYangBHanY, et al.Toward understanding the fractured mechanism in laser welded–brazed Al/steel interface by in–situ SEM tensile observations. J Mater Process Technol2024; 325: 118294.
15.
HeHWuCLinS, et al.Pulsed TIG welding–brazing of aluminum–stainless steel with an Al-Cu twin hot wire. J Mater Eng Perform2019; 28: 1180–1189.
16.
SpringerHKostkaAPaytonEJ, et al.On the formation and growth of intermetallic phases during interdiffusion between low-carbon steel and aluminum alloys. Acta Mater2011; 59: 1586–1600.
17.
AlikhaniABeygiRMehriziMZ, et al.Effect of Mg and Si on intermetallic formation and fracture behavior of pure aluminum-galvanized carbon-steel joints made by weld-brazing. J Cent South Univ2021; 28: 3626–3638.
18.
YangJLiYLZhangH, et al.Control of interfacial intermetallic compounds in Fe–Al joining by Zn addition. Mater Sci Eng A2015; 645: 323–327.
19.
TanCZangCXiaH, et al.Influence of Al additions in Zn–based filler metals on laser welding–brazing of Al/Steel. J Manuf Process2018; 34: 251–263.
20.
MarderAR. The metallurgy of Zn-coated steel. Prog Mater Sci2000; 45: 191–271.
21.
ZhangYLiFGuoG, et al.Effects of different powders on the micro-gap laser welding-brazing of an aluminium-steel butt joint using a coaxial feeding method. Mater Des2016; 109: 10–18.
22.
HongSMTashiroSBangHS, et al.Effect of gap bridging distance on the weldability of aluminum alloy to galvanized steel joints in AC pulse GMAW. Met Mater Int.2023; 29: 1133–1144.
23.
BoldrinDAVIDEColopiMD'ArcangeloS, et al.High speed videography of gap bridging with beam oscillation and wire feeding during the laser welding of stainless steel and aluminum alloys.Lasers Manuf Conf 2021;1–10. doi:10.1117/12.948680
24.
GatzenMRadelTThomyC,et al.The role of zinc layer during wetting of aluminium on zinc-coated steel in laser brazing and welding. Phys Procedia2014; 56: 730–739.
25.
SunJYanQGaoW, et al.Investigation of laser welding on butt joints of Al/steel dissimilar materials. Mater Des2015; 83: 120–128.
26.
GatzenMRadelTThomyC,et al.The role of zinc layer during wetting of aluminium on zinc-coated steel in laser brazing and welding. Phys Procedia2014; 56: 730–739.
27.
GatzenMRadelTThomyC,et al.Wetting behavior of eutectic Al–Si droplets on zinc coated steel substrates. J Mater Process Technol2014; 214: 123–131.
28.
ArghavaniMRMovahediMKokabiAH. Role of zinc layer in resistance spot welding of aluminium to steel. Mater Des2016; 102: 106–114.
29.
JiaLShichunJYanS, et al.Effects of zinc on the laser welding of an aluminum alloy and galvanized steel. J Mater Process Technol2015; 224: 49–59.
30.
SundmanBOhnumaIDupinN, et al.An assessment of the entire Al–Fe system including D03 ordering. Acta Mater2009; 57: 2896–2908.
31.
ShuFNiuSZhuB, et al.Effect of pulse frequency on the nanosecond pulsed laser welded Al/steel lapped joint. Opt Laser Technol2021; 143: 107355.
32.
PascheGScheelMSchäublinR, et al.Time-resolved X-ray microtomography observation of intermetallic formation between solid Fe and liquid Al. Metall Mater Trans A2013; 44: 4119–4123.
33.
GrongØSandnesLBerghT, et al.An analytical framework for modelling intermetallic compound (IMC) formation and optimising bond strength in aluminium-steel welds. Mater Des Process Commun2019; 1: 57.
34.
DengSYuanRTangX, et al.Migration behavior of IMC layer in twin-spot laser welding-brazing of aluminum to steel. Mater Des2020; 188: 108489.
35.
NguyenQMHuangSC. An investigation of the microstructure of an intermetallic layer in welding aluminum alloys to steel by MIG process. Materials2015; 8: 8246–8254.
36.
YinFZhaoMLiuY, et al.Effect of Si on growth kinetics of intermetallic compounds during reaction between solid iron and molten aluminum. Trans Nonferrous Met Soc China2013; 23: 556–561.
37.
TanCZangCXiaH, et al.Influence of Al additions in Zn–based filler metals on laser welding–brazing of Al/steel. J Manuf Process2018; 34: 251–263.
38.
ZhuYWang HPWangY, et al.Formation mechanism of liquid metal embrittlement in laser lap welding of Zn-coated GEN3 steels. Mater Sci Eng A2021; 800: 140229.
39.
ZhangHLiuJ. Microstructure characteristics and mechanical property of aluminum alloy/stainless steel lap joints fabricated by MIG welding-brazing process. Mater Sci Eng A2011; 528: 6179–6185.
