This paper presents a process–structure–property relationship study of laser welds as a continuous consolidation method for joining thin monophased steel foils, thereby providing a more effective, less costly method to construct automotive catalytic converters. A body centred cubic (bcc) iron–chromium–aluminium alloy doped with Mischmetal was utilised in this study. Both pulsed and continuous wave modes were used to establish the limit welding diagrams for lap joint configuration. Actual laser welding parameters were selected using several testing conditions. The laser welds behaved substantially different from the base material under creep and high temperature oxidation. The difference was mainly attributed to the changes in grain morphology, precipitation of aluminium nitrides and carbides, and relocalisation of the reactive elements during liquid metal flow upon keyhole formation, solidification and cooling.
XuZ, YiJ, WooldridgeS, ReicheD, CurtisE, PapaioannouG: ‘SI combustion and direct injection SI engine technology’, SP SP-2241, 349–369; 2009, Warrendale, PA, Society of Automotive Engineers.
7.
NakouziSR, McBrideJR, NieteringKE, VisserJH, AdamczykAAJr, NarulaCK: Proc. Materials Research Society Symp.: ‘Advanced catalytic materials’, Boston, MA, USA, December 1996, Materials Research Society, Vol. 454, 283–289.
ChenL, JhaB: ‘Advanced catalysts’, SP-1864, 109–116; 2004, Warrendale, PA, Society of Automotive Engineers.
13.
SimmsNJ, NortonJF, McColvinG: ‘Novel approaches to improving high temperature corrosion resistance’, European Federation of Corrosion Series No. 4736–64; 2008, Cambridge, Woodhead Publishing Limited.
El KadiriH: ‘Mechanisms of High Temperature Oxidation in Alumina-Forming Alloys’, PhD thesis, Ecole des Mines de Paris at the Materials Center, Paris, France, 2004.
TadmorR: J. Colloid Interface Sci., 2009, 332, (2), 451–454.
43.
ToguriJM, IpSW: Proc. Alex McLean Symp., Toronto, Ont., Canada, July 1998, Iron and Steel Society, Warrendale, PA, 77–86.
44.
WeiPS, ChungFK: Metall. Mater. Trans. B, 2000, 31B, (6), 1387–1403.
45.
LampmanS: ‘Weld integrity and performance’; 1997, Materials Park, OH, ASM International.
46.
SemakV, MatsunawaA: J. Phys. D, 1997, 30D, (18), 2541–2552.
47.
El KadiriH, HorstemeyerMF, BammannDJ: J. Mech. Phys. Solids, 2008, 56, (12), 3392–3415.
48.
El KadiriH, MolinsR, BienvenuY: Mater. Sci. Forum, 2004, 461–464, 1107–1116.
49.
JedlinskiJ: Solid State Ionics, 1997, 101–103, (Pt 2), 1033–1040.
50.
El KadiriH, BienvenuY, SolankiK, HorstemeyerMF, WangPT: ‘Creep and tensile behaviors of Fe–Cr–Al foils and laser microwelds at high temperature’, Mater. Sci. Eng. A, 2006, A421, (1), 168–181.
51.
GermidisA: ‘Comportement thermomécanique de structures alvéolaires pour pots catalytiques’, PhD thesis, Centre des Matériaux, Ecole Nationale Supérieure des Mines de Paris, ENSMP, Paris, France, 1996.
