Enabling Dissimilar Joining of Coated Steels to Aluminum through Impact Spot Welding

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Enabling Dissimilar Joining of Coated Steels to Aluminum through Impact Spot Welding

Kapil, Angshuman / Vivek, Anupam / Daehn, Glenn / Mao, Yu

Direct welding of coated steels to aluminum alloys is challenging due to high energy requirements, decreased weldability, and unstable weld quality. The present study reports the application of a new design approach in vaporizing foil actuator welding (VFAW), where an asymmetric preform shape on the target sheet generated the requisite standoff, enabling direct spot welding of a typical automotive aluminum alloy (6022 T4) and two different zinc-coated steels, galvanized high-strength low-alloy 350 and galvannealed dual-phase 590. The use of the new approach enabled for the first time the ability to spot weld through coating without any preweld surface preparation. Characterization using lap-shear and peel testing revealed strong joints for both the weld pairs (AA 6022 T4-HSLA 350 and AA 6022 T4-DP 590). The weld interface characterized by scanning electron microscopy (SEM) revealed a hierarchical structure and the presence of a typical wavy region.

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Title :

Enabling Dissimilar Joining of Coated Steels to Aluminum through Impact Spot Welding

Additional title:

Sae Int. J. Mater. Manf
Sae International Journal of Materials and Manufacturing

Contributors:

Kapil, Angshuman (author) / Vivek, Anupam (author) / Daehn, Glenn (author) / Mao, Yu (author)

Published in:

Sae International Journal of Materials and Manufacturing ; 14 , 1 ; 33-43

Publication date :

2020-09-09

Size :

11 pages

ISSN :

1946-3987 , 1946-3979

DOI :

https://doi.org/10.4271/05-14-01-0004

Type of media :

Conference paper

Type of material :

Language :

English

Keywords :

Aluminum alloys

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