Aluminum-Steel Dissimilar Welding
- Edison Welding Institute
- Postdoctoral Researcher
- Dr. Emel Taban, University of Kocaeli, Turkey
- Dr. Jerry Gould
The development of sound metallurgical bonds between steel and aluminum is a significant materials joining challenge due to large differences in both physical and metallurgical properties. Metallurgically, joints between aluminum and steel can result in the formation of multiple intermetallic phases that generally nucleate and grow at elevated temperature in the solid state. These intermetallics usually result in mechanical degradation of the joint, since they tend to be quite brittle relative to the matrix. The formation of these phases is mainly driven by interdiffusion of Fe and Al, and is highly dependent on the specific time and temperature history of the welding process. Weld thermal cycles that result in higher temperatures and/or slow cooling times to room temperature are often associated with processes that result in the formation of thick intermetallic compound (IMC) layers at the joint interface. The formation of these IMCs is generally considered the root cause for the property degradation experienced with these types of joints.
In this study friction welds between aluminum alloy 6061-T6 and AISI 1018 steel were evaluated. Joints were successfully produced in this combination and the intermetallic compounds FeAl and Fe2Al5 were observed at the interface. These joints were then subjected to thermo-mechanical treatment in the Gleeble in order to determine the rate of growth and evolution of these IMCs under different thermo-mechanical processing conditions. Using scanning and transmission electron microscopy the evolution and growth of FeAl, Fe2Al5, FeAl3, and FeAl6 was investigated.
- E. Taban, J.E. Gould, and J.C. Lippold. 2009. Characterization of 6061-T6 aluminum alloy to AISI steel interfaces during joining and thermo-mechanical conditioning, Materials Science and Engineering A, 527:1704-1708.
- E. Taban, J.E. Gould, and J.C. Lippold. 2010. Dissimilar friction welding of 6061-T6 aluminum and AISI steel: properties and microstructural characterization, Materials and Design, 31:2305-2311.