Abstract

The dissimilar welding of aluminum alloy and steel has become increasingly attractive in the automotive industry for achieve lightweight components. However, welding of these dissimilar materials is difficult when using conventional fusion welding due to differences in thermo-physical properties and the formation of intermetallic compounds (IMCs) at the Al–Fe joint interface. In this study, the dissimilar welding of 2.0-mm thick sheets of aluminum alloy (AA5052) and steel (SPFC780DP) sheets was carried out using hybrid friction stir welding (HFSW) with an additional heat source of gas tungsten arc welding (GTAW). Furthermore, the effects of process parameters on the mechanical and microstructure characteristics of joint were investigated. The results showed that the maximum tensile strength of the joint was 199 MPa, which exhibited a joint efficiency of about 90% of compared to the aluminum alloy base metal. A thin interfacial layer with a thickness of about 1.0 µm, consisting of Fe₃Al and FeAl₃ IMCs, was observed at the joint interface through SEM–EDS analysis, indicating an acceptable range for the thickness of IMCs.

中文翻译：

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AA5052和SPFC780DP钢混合搅拌摩擦焊异种接头的焊接性能

摘要

铝合金和钢的异种焊接在汽车工业中对于实现轻量化部件越来越有吸引力。然而，由于热物理性质的差异以及铝-铁接头界面处金属间化合物（IMC）的形成，使用传统熔焊焊接这些异种材料是很困难的。在本研究中，采用混合搅拌摩擦焊 (HFSW) 和气体保护钨极电弧焊 (GTAW) 附加热源，对 2.0 毫米厚的铝合金 (AA5052) 和钢板 (SPFC780DP) 进行异种焊接。此外，还研究了工艺参数对接头机械和微观结构特性的影响。结果表明，接头的最大抗拉强度为199 MPa，与铝合金母材相比，接头效率约为90%。通过SEM-EDS分析，在接头界面处观察到由Fe ₃ Al和FeAl ₃ IMCs组成的厚度约为1.0 µm的薄界面层，表明IMCs的厚度在可接受的范围内。