Pulsed TIG Welding–Brazing of Aluminum–Stainless Steel with an Al-Cu Twin Hot Wire
Source abstract
Abstract
A TIG welding–brazing process with a twin aluminum hot wire technique was utilized to control the heat input, improve the joint formation, suppress the interfacial intermetallic compounds (IMCs) and increase the joint strength, thereby creating reliable joints between an aluminum alloy and stainless steel with an ER2319 filler. Twin wires with reasonable diameters and filling modes led to a satisfactory weld of parent metals with varying thicknesses. By the hot wire technique, the reasonable range of the welding current was extended and the thickness of the interfacial IMC at the seam bottom was reduced. In addition, both the tensile strength and stability of the joints increased compared with a cold wire. The IMC consisted of θ-(Fe,Cu)4Al13 and minor Cr0.7Fe0.3Al6, and the precipitated phases in the weld were Al2Cu and Al2CuMg. With an increasing welding current, the IMC thickness significantly increased, while the joint strength decreased. The fracture positions of the joints varied with the corresponding welding currents.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced Welding Techniques Analysis · Aluminum Alloy Microstructure Properties · Welding Techniques and Residual Stresses
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (55)
Show source-provided references
1. K. Saida, H. Ohnishi, and K. Nishimoto, Fluxless Laser Brazing of Aluminium Alloy to Galvanized Steel Using a Tandem Beam-Dissimilar Laser Brazing of Aluminium Alloy and Steels, Weld. Int., 2010, 24(3), p 161–16810.1080/09507110902843065 ↗
2. A. Mathieu, S. Pontevicci, J. Viala, E. Cicala, S. Matte, and D. Grevey, Laser Brazing of A Steel/Aluminium Assembly with Hot Filler Wire (88% Al, 12% Si), Mat. Sci. Eng. A, 2006, 435, p 19–2810.1016/j.msea.2006.07.099 ↗
3. H. Zhang and J. Liu, Microstructure Characteristics and Mechanical Property of Aluminium alloy/Stainless Steel Lap Joints Fabricated by MIG Welding-Brazing Process, Mat. Sci. Eng. A, 2011, 528(19-20), p 6179–618510.1016/j.msea.2011.04.039 ↗
4. J.L. Song, S.B. Lin, C.L. Yang, G.C. Ma, and H. Liu, Spreading Behavior and Microstructure Characteristics of Dissimilar Metals TIG Welding-Brazing of Aluminum Alloy to Stainless Steel, Mat. Sci. Eng. A, 2009, 509(1-2), p 31–4010.1016/j.msea.2009.02.036 ↗
5. L. Agudo, D. Eyidi, C.H. Schmaranzer, E. Arenholz, N. Jank, J. Bruckner, and A.R. Pyzalla, Intermetallic FexAly-Phases in a Steel/Al-Alloy Fusion Weld, J. Mater. Sci., 2007, 42(12), p 4205–421410.1007/s10853-006-0644-0 ↗
6. X. Li, A. Scherf, M. Heilmaier, and F. Stein, The Al-Rich Part of the Fe-Al Phase Diagram, J. Phase Equilib. Diffus., 2016, 37(2), p 162–17310.1007/s11669-015-0446-7 ↗
7. E.R. Naimon, J.H. Doyle, C.R. Rice, D. Vigil, and D.R. Walmsley, Diffusion Welding of Aluminum to Stainless Steel, Weld. J., 1981, 60(11), p 17–20
8. J.H. Kong, M. Okumiya, Y. Tsunekawa, K.Y. Yun, S.G. Kim, and M. Yoshida, A Novel Bonding Method of Pure Aluminum and SUS304 Stainless Steel Using Barrel Nitriding, Metall. Mater. Trans. A, 2014, 45(10), p 4443–445310.1007/s11661-014-2380-4 ↗
9. H. Yu and Y. Tong, Magnetic Pulse Welding of Aluminum to Steel Using Uniform Pressure Electromagnetic Actuator, Int. J. Adv. Manuf. Tech., 2017, 91(5-8), p 2257–226510.1007/s00170-016-9928-y ↗
10. M.B. Uday, M.N. Ahmad Fauzi, H. Zuhailawati, and A.B. Ismail, Advances in Friction Welding Process: a Review, Sci. Technol. Weld. Join., 2010, 15(7), p 534–55810.1179/136217110X12785889550064 ↗
11. W. Li, A. Vairis, M. Preuss, and T. Ma, Linear and Rotary Friction Welding Review, Int. Mater. Rev., 2016, 61(2), p 71–10010.1080/09506608.2015.1109214 ↗
12. A. Simar and M.-N. Avettand-Fènoël, State of the Art about Dissimilar Metal Friction Stir Welding, Sci. Technol. Weld. Join., 2017, 22(5), p 389–40310.1080/13621718.2016.1251712 ↗
13. T. Debroy and H.K.D.H. Bhadeshia, Friction Stir Welding of Dissimilar Alloys-a Perspective, Sci. Technol. Weld. Join., 2010, 15(4), p 266–27010.1179/174329310X12726496072400 ↗
14. M. Reddy, S. Rao, and T. Mohandas, Role of Electroplated Interlayer in Continuous Drive Friction Welding of AA6061 to AISI, 304 Dissimilar Metals, Sci. Technol. Weld. Join., 2008, 13(7), p 619–62810.1179/174329308X319217 ↗
15. G. Zhang, W. Su, J. Zhang, and Z. Wei, Friction Stir Brazing: a Novel Process for Fabricating Al/Steel Layered Composite and for Dissimilar Joining of Al to Steel, Metall. Mater. Trans. A, 2011, 42(9), p 2850–286110.1007/s11661-011-0677-0 ↗
16. F.W. Bach, A. Beniyash, K. Lau, and R. Versemann, Joining of Steel-Aluminium Hybrid Structures with Electron Beam on Atmosphere, Adv. Mater. Res., 2005, 6, p 143–15010.4028/www.scientific.net/AMR.6-8.143 ↗
17. P. Wang, X. Chen, Q. Pan, B. Madigan, and J. Long, Laser Welding Dissimilar Materials of Aluminum to Steel: an Overview, Int. J. Adv. Manuf. Tech., 2016, 87(9), p 3081–309010.1007/s00170-016-8725-y ↗
18. Y. Zhang, J. Huang, Z. Cheng, Z. Ye, H. Chi, L. Peng, and S. Chen, Study on MIG-TIG Double-Sided Arc Welding-Brazing of Aluminum and Stainless Steel, Mater. Lett., 2016, 172, p 146–14810.1016/j.matlet.2016.02.146 ↗
19. Y. Shi, G. Zhang, Y. Huang, L. Lu, J. Huang, and Y. Shao, Pulsed Double-Electrode GMAW-Brazing for Joining of Aluminum to Steel, Weld. J., 2014, 93(6), p 216–224
20. S. Madhavan, M. Kamaraj, and L. Vijayaraghavan, Microstructure and Mechanical Properties of Cold Metal Transfer Welded Aluminium/Dual Phase Steel, Sci. Technol. Weld. Join., 2016, 21(3), p 194–20010.1179/1362171815Y.0000000082 ↗
21. G. Qin, Y. Su, X. Meng, and B. Fu, Numerical Simulation on MIG Arc Brazing-fusion Welding of Aluminum Alloy to Galvanized Steel Plate, Int. J. Adv. Manuf. Tech., 2015, 78(9), p 1917–192510.1007/s00170-014-6529-5 ↗
22. H. Ma, G. Qin, X. Bai, L. Wang, and Z. Liang, Effect of Initial Temperature on Joint of Aluminum Alloy to Galvanized Steel Welded by MIG Arc Brazing-fusion Welding Process, Int. J. Adv. Manuf. Tech., 2016, 86(9), p 3135–314310.1007/s00170-016-8425-7 ↗
23. S. Lin, J. Song, C. Yang, C. Fan, and D. Zhang, Brazability of Dissimilar Metals Tungsten Inert Gas Butt Welding-brazing between Aluminum Alloy and Stainless Steel with Al-Cu Filler Metal, Mater. Des., 2010, 31(5), p 2637–264210.1016/j.matdes.2009.12.005 ↗
24. J. Yang, Y. Li, H. Zhang, W. Guo, and Y. Zhou, Control of Interfacial Intermetallic Compounds in Fe-Al Joining by Zn Addition, Mat. Sci. Eng. A, 2015, 645, p 323–32710.1016/j.msea.2015.08.036 ↗
25. Y. Su, X. Hua, and Y. Wu, Influence of Alloy Elements on Microstructure and Mechanical Property of Aluminum-Steel Lap Joint Made by Gas Metal Arc Welding, J. Mater. Process. Tech., 2014, 214(4), p 750–75510.1016/j.jmatprotec.2013.11.022 ↗
26. L.A. Jácome, S. Weber, A. Leitner, E. Arenholz, J. Bruckner, H. Hackl, and A.R. Pyzalla, Influence of Filler Composition on the Microstructure and Mechanical Properties of Steel-Aluminum Joints Produced by Metal Arc Joining, Adv. Eng. Mater., 2009, 11(5), p 350–35810.1002/adem.200800319 ↗
27. H. Springer, A. Szczepaniak, and D. Raabe, On the Role of Zinc on the Formation and Growth of Intermetallic Phases During Interdiffusion Between Steel and Aluminium alloys, Acta Mater., 2015, 96, p 203–21110.1016/j.actamat.2015.06.028 ↗
28. S. Chen, J. Huang, K. Ma, X. Zhao, and A. Vivek, Microstructures and Mechanical Properties of Laser Penetration Welding Joint With/Without Ni-Foil in an Overlap Steel-on-Aluminum Configuration, Metall. Mater. Trans. A, 2014, 45(7), p 3064–307310.1007/s11661-014-2241-1 ↗
29. S. Chen, Z. Zhai, J. Huang, X. Zhao, and J. Xiong, Interface Microstructure and Fracture Behavior of Single/Dual-beam Laser Welded Steel-Al Dissimilar Joint Produced with Copper Interlayer, Int. J. Adv. Manuf. Tech., 2016, 82(1-4), p 631–64310.1007/s00170-015-7390-x ↗
30. B. Mezrag, F. Deschaux-Beaume, and M. Benachour, Control of Mass and Heat Transfer for Steel/Aluminium Joining Using Cold Metal Transfer Process, Sci. Technol. Weld. Join., 2015, 20(3), p 189–19810.1179/1362171814Y.0000000271 ↗
31. R. Borrisutthekul, T. Yachi, Y. Miyashita, and Y. Mutoh, Suppression of Intermetallic Reaction Layer Formation by Controlling Heat Flow in Dissimilar Joining of Steel and Aluminum Alloy, Mat. Sci. Eng. A, 2007, 467(1-2), p 108–11310.1016/j.msea.2007.03.049 ↗
32. M. Rathod and M. Kutsuna, Joining of Aluminum Alloy 5052 and Low-carbon Steel by Laser Roll Welding, Weld. J., 2004, 83(1), p 16–26
33. S. Zinn and S.L. Semiatin, Elements of Induction Heating: Design, Control, and Applications, ASM International, Russell Township, 198810.31399/asm.tb.eihdca.9781627083416 ↗
34. J. Song, S. Lin, C. Yang, C. Fan, and G. Ma, Analysis of Intermetallic Layer in Dissimilar TIG Welding-Brazing Butt Joint of Aluminium Alloy to Stainless Steel, Sci. Technol. Weld. Join., 2010, 15(3), p 213–21810.1179/136217110X12665048207610 ↗
35. J.L. Murray, The Al-Cr (Aluminum-Chromium) System, J. Phase Equilib., 1998, 19(4), p 367–37510.1007/BF02735058 ↗
36. Fvd Woude and P.J. Schurer, A Study of Quasi-crystalline Al-Fe Alloys by Mössbauer-effect Spectroscopy and Diffraction Techniques, Can. J. Phys., 1987, 65(10), p 1301–130810.1139/p87-205 ↗
37. K. Barmak and V. Dybkov, Interaction of Iron-chromium Alloys Containing 10 and 25 Mass% Chromium with Liquid Aluminium Part II, Formation of Intermetallic Compounds, J. Mater. Sci., 2004, 39(13), p 4219–423010.1023/B:JMSC.0000033402.37206.27 ↗
38. S.C. Wang and M.J. Starink, Precipitates and Intermetallic Phases in Precipitation Hardening Al-Cu-Mg-(Li) Based Alloys, Int. Mater. Rev., 2005, 50(4), p 193–21510.1179/174328005X14357 ↗
39. C. Zhang, M. Gao, G. Li, C. Chen, and X. Zeng, Strength Improving Mechanism of Laser Arc Hybrid Welding of Wrought AA 2219 Aluminium Alloy using AlMg5 Wire, Sci. Technol. Weld. Join., 2013, 18(8), p 703–71010.1179/1362171813Y.0000000153 ↗
40. J. Li, Research on Technology of Variable Polarity Plasma Arc Welding with Twin-wire Filler, Master Thesis, Harbin Institute of Technology (2009)
41. Z. Sun, M. Kuo and D. P, Twin Wire Gas Tungsten Arc Cladding, SIMTech Technical Report (PT/99/004/JT) (1999)
42. Z. Ye, J. Huang, Z. Cheng, W. Gao, Y. Zhang, S. Chen, and J. Yang, Combined Effects of MIG and TIG Arcs on Weld Appearance and Interface Properties in Al/steel Double-sided Butt Welding-brazing, J. Mater. Process. Technol., 2017, 250, p 25–3410.1016/j.jmatprotec.2017.07.003 ↗
43. J. Xue, Y. Li, H. Chen, and Z. Zhu, Effects of Heat Input on Wettability, Interface Microstructure and Properties of Al/steel Butt Joint in Laser-metal Inert-gas Hybrid Welding-brazing, J. Mater. Process. Technol., 2018, 255, p 47–5410.1016/j.jmatprotec.2017.11.063 ↗
44. L. Li, H. Xia, C. Tan, and N. Ma, Effect of Groove Shape on Laser Welding-brazing Al to Steel, J. Mater. Process. Technol., 2018, 252, p 573–58110.1016/j.jmatprotec.2017.10.025 ↗
45. L. Shao, Y. Shi, J.K. Huang, and S.J. Wu, Effect of Joining Parameters on Microstructure of Dissimilar Metal Joints Between Aluminum and Galvanized Steel, Mater. Des., 2015, 66, p 453–45810.1016/j.matdes.2014.06.026 ↗
46. E. Ünel and E. Taban, Properties and Optimization of Dissimilar Aluminum Steel CMT Welds, Weld. World, 2017, 61(1), p 1–910.1007/s40194-016-0386-9 ↗
47. S. Meco, S. Ganguly, S. Williams, and N. Mcpherson, Effect of Laser Processing Parameters on the Formation of Intermetallic Compounds in Fe-Al Dissimilar Welding, J. Mater. Eng. Perform., 2014, 23(9), p 3361–337010.1007/s11665-014-1106-5 ↗
48. J. Sun, Q. Yan, W. Gao, and J. Huang, Investigation of Laser Welding on Butt Joints of Al/steel Dissimilar Materials, Mater. Des., 2015, 83, p 120–12810.1016/j.matdes.2015.05.069 ↗
49. U. Reisgen, C. Otten, and J. Schoenberger, Investigations about the Influence of the Time-temperature Curve on the Formation of Intermetallic Phases During Electron Beam Welding of Steel-Aluminium Material Combinations, Weld. World, 2014, 58(4), p 443–45410.1007/s40194-014-0128-9 ↗
50. V.S. Zolotorevsky, N.A. Belov, and M.V. Glazoff, Casting Aluminum Alloys, Elsevier Science, Amsterdam, 200710.1016/B978-008045370-5.50007-9 ↗
51. Z. Ye, J. Huang, W. Gao, Y. Zhang, Z. Cheng, S. Chen, and J. Yang, Microstructure and Mechanical Properties of 5052 Aluminum Alloy/Mild Steel Butt Joint Achieved by MIG-TIG Double-sided Arc Welding-Brazing, Mater. Des., 2017, 123, p 69–7910.1016/j.matdes.2017.03.039 ↗
52. E. Schubert, M. Klassen, I. Zerner, C. Walz, and G. Sepold, Light-weight Structures Produced by Laser Beam Joining for Future Applications in Automobile and Aerospace Industry, J. Mater. Process. Technol., 2001, 115(1), p 2–810.1016/S0924-0136(01)00756-7 ↗
53. H. He, S. Lin, C. Yang, C. Fan, and Z. Chen, Combination Effects of Nocolok Flux with Ni Powder on Properties and Microstructures of Aluminum-Stainless Steel TIG Welding-Brazing Joint, J. Mater. Eng. Perform., 2013, 22(11), p 3315–332310.1007/s11665-013-0615-y ↗
54. M. Yan and Z. Fan, Review Durability of Materials in Molten Aluminum Alloys, J. Mater. Sci., 2001, 36(2), p 285–29510.1023/A:1004843621542 ↗
55. C. Tan, J. Yang, X. Zhao, K. Zhang, X. Song, B. Chen, L. Li, and J. Feng, Influence of Ni Coating on Interfacial Reactions and Mechanical Properties in Laser Welding-brazing of Mg/Ti Butt Joint, J. Alloys Compd., 2018, 764, p 186–20110.1016/j.jallcom.2018.06.039 ↗