Achieving superior aluminum-steel dissimilar joining via ultrasonic spot welding: Microstructure and fracture behavior

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY Materials Science and Engineering: A Pub Date : 2024-11-01 DOI:10.1016/j.msea.2024.147489

D. Bajaj , R. Mehavarnam , X.F. Fang , N.S. Ma , D.Y. Li , D.L. Chen

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Abstract

High-strength dissimilar welded joints of AA2024-T3 alloy with an AA1230 coating and galvanized high-strength low-alloy (HSLA) steel were attained through ultrasonic spot welding (USW) in this study. The tensile lap shear failure loads over a welding energy range between 2000 J and 3000 J were observed to meet or surpass the values specified in the AWS D17.2 standard. The highest average tensile lap shear strength was obtained to be ∼169 MPa due to the formation of a ∼30–70 μm thick Al-Zn diffusion layer without the presence of intermetallic compounds. The substrate failure from the softer AA1230 coating on the AA2024 side under tensile loading and cyclic loading at higher cyclic loads was observed, which reflected a robust sticking capability. The partial failure from AA1230 coating consisted of characteristic shear dimples, allowing high plasticity upon shear deformation. While the 1000 J welds failed mainly via substrate failure from AA1230 and transverse through-thickness (TTT) cracking in AA2024, the cohesive failure across the Al-Zn diffusion layer and adhesive failure from the Al-Fe-intermetallic/Al-Zn-diffusion layer interface were observed in the welds made at 3000 J, corresponding to the superior bonding strength and longer fatigue life.

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通过超声波点焊实现卓越的铝-钢异种连接：微观结构和断裂行为

本研究通过超声波点焊（USW）实现了带有 AA1230 涂层的 AA2024-T3 合金和镀锌高强度低合金（HSLA）钢的高强度异种焊接接头。在 2000 J 至 3000 J 的焊接能量范围内，观察到的拉伸搭接剪切破坏载荷达到或超过了 AWS D17.2 标准规定的值。由于形成了厚度为 30-70 μm 的铝锌扩散层，且不存在金属间化合物，因此获得的最高平均拉伸搭接剪切强度为 169 MPa。在拉伸载荷和较高循环载荷下，观察到 AA2024 侧较软的 AA1230 涂层基体失效，这反映了较强的粘附能力。AA1230 涂层的部分失效由特征性剪切凹痕组成，在剪切变形时具有高塑性。虽然 1000 J 的焊缝主要通过 AA1230 的基底失效和 AA2024 的横向通厚 (TTT) 裂纹失效，但在 3000 J 的焊缝中观察到了铝锌扩散层的内聚失效和铝铁金属间化合物/铝锌扩散层界面的粘合失效，这与更高的粘合强度和更长的疲劳寿命相对应。

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来源期刊

Materials Science and Engineering: A 工程技术-材料科学：综合

CiteScore

11.50

自引率

15.60%

发文量

1811

审稿时长

31 days

期刊介绍： Materials Science and Engineering A provides an international medium for the publication of theoretical and experimental studies related to the load-bearing capacity of materials as influenced by their basic properties, processing history, microstructure and operating environment. Appropriate submissions to Materials Science and Engineering A should include scientific and/or engineering factors which affect the microstructure - strength relationships of materials and report the changes to mechanical behavior.