The Effect of Welding Current and Electrode Force on the Heat Input, Weld Diameter, and Physical and Mechanical Properties of SS316L/Ti6Al4V Dissimilar Resistance Spot Welding with Aluminum Interlayer
Abstract
:1. Introduction
2. Materials and Method
3. Results and Discussion
3.1. Heat Input and Physical Properties Analysis
3.2. Tensile-Shear Test
3.3. Welded Joint Morphology
3.3.1. Cross-Sectional Morphology
3.3.2. Microstructure Examination
3.3.3. The Effect of Welding Parameters on the Interlayer
3.4. Chemical Composition Analysis
3.5. Microhardness Test
4. Conclusions
- As the welding current and the electrode force increased, the generated heat input on the resistance spot welded samples also increased. The effect of a higher generated heat input affected several joint qualities, such as a greater weld nugget diameter, massive spatter and expulsion on the highest heat input, microhardness value, and the microstructure and chemical composition of the entire joint morphology. Meanwhile, the highest joint strength of 8.71 kN was achieved at the lowest heat input of the 11 kA welding current, 3 kN electrode force, and 30 cycles of welding time and holding time.
- High welding current and electrode force also affected the microstructure morphology. The lathy and acicular delta-ferrite (δ) phases were found in the low heat input sample at the stainless steel interface. Meanwhile, the dendritic delta-ferrite (δ) phase was found to be more dominant at the high heat input of the stainless steel interface. The titanium morphology consisted of acicular α’ martensite and a dominant β phase transformation, which is the primary cause of the increase of the microhardness value. Meanwhile, the interlayer thickness significantly decreased due to the applied high welding current and high electrode force. The higher heat input caused the over-melted aluminum interlayer, and the higher electrode force convincingly suppressed the interlayer to the smaller thickness. These factors lead to a decrease in joint strength and joint quality.
- The chemical composition analysis showed that the higher welding current and electrode force are prone to produce better diffusion-reaction between the base metals and the interlayer. The formation of Fe3Al and Ti3Al were successfully exhibited at the intermetallic compound layer of the SS/Al and Ti/Al interfaces for both samples. Additionally, the diffusion-reaction rate at sample 3, which was welded with the highest welding current and highest electrode force, was found to be significantly higher than that of the samples welded with low welding current and electrode force.
- The microhardness value was found to be relatively higher at the sample which implemented the highest welding current and electrode force. The excessive generated heat input and rapid cooling temperature, that caused microstructural transformation, led to the increase of the microhardness value. The highest microhardness value in this study was recorded at 214.5 HV of the stainless steel side and 347.5 HV of the titanium alloy side.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Element | Cr | Ni | Mn | Mo | Fe | Al | Ti | V | C | O | N | Mg |
---|---|---|---|---|---|---|---|---|---|---|---|---|
SS316L | 17.68 | 12.6 | 1.53 | 2.38 | Bal. | 0.018 | 0.021 | 0.663 | 0.016 | - | - | - |
Ti6Al4V | - | - | - | - | 0.4 | 6.75 | Bal. | 4.5 | 0.08 | 0.02 | 0.05 | - |
AA5754 | 0.3 | - | 0.5 | - | 0.4 | 93.6 | 0.15 | - | - | - | - | 3.6 |
Welding Parameter | Weld Current (kA) | Welding Time (Cycles) | Holding Time (Cycles) | Electrode Force (kN) |
---|---|---|---|---|
Sample 1 | 11 | 30 | 30 | 3 |
Sample 2 | 12 | 4 | ||
Sample 3 | 13 | 5 |
Spectrum | Composition (wt %) | ||||||||
---|---|---|---|---|---|---|---|---|---|
Fe | Cr | Ni | O | C | Al | Na | Cu | Ti | |
1 | 70.1 | 17.8 | 10.7 | 1.4 | - | - | - | - | - |
2 | 40.6 | 12.2 | 5.8 | 13.6 | 9.7 | - | 9.3 | 8.8 | - |
3 | 55.2 | 13.8 | 7.0 | 6.5 | 8.9 | 4.8 | 3.2 | - | 0.5 |
Spectrum | Composition (wt %) | |||||
---|---|---|---|---|---|---|
Ti | Al | V | C | O | Fe | |
1 | 91.0 | 5.4 | 3.6 | - | - | - |
2 | 87.5 | 5.6 | 3.6 | 3.3 | - | - |
3 | 28.5 | 35.3 | 1.2 | 15.8 | 18.6 | 0.6 |
Spectrum | Composition (wt %) | ||||||
---|---|---|---|---|---|---|---|
Fe | Ti | Cr | Ni | C | Al | V | |
1 | 55.2 | 14.2 | 14.2 | 8.8 | 6.2 | 1.4 | - |
2 | 18.8 | 60.2 | 3.2 | 4.1 | - | 11.2 | 2.5 |
3 | 4.3 | - | 1.5 | - | 13.8 | 80.4 | - |
Spectrum | Composition (wt %) | |||||||
---|---|---|---|---|---|---|---|---|
Ti | Al | V | C | O | Fe | Cu | Cr | |
1 | 87.4 | 5.5 | 4.1 | 3.0 | - | - | - | - |
2 | 19.6 | 35.8 | - | 29.1 | 9.0 | 3.6 | 1.6 | 1.3 |
3 | 0.6 | 76.6 | - | 18.3 | 2.7 | 1.8 | - | - |
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Taufiqurrahman, I.; Ahmad, A.; Mustapha, M.; Lenggo Ginta, T.; Ady Farizan Haryoko, L.; Ahmed Shozib, I. The Effect of Welding Current and Electrode Force on the Heat Input, Weld Diameter, and Physical and Mechanical Properties of SS316L/Ti6Al4V Dissimilar Resistance Spot Welding with Aluminum Interlayer. Materials 2021, 14, 1129. https://doi.org/10.3390/ma14051129
Taufiqurrahman I, Ahmad A, Mustapha M, Lenggo Ginta T, Ady Farizan Haryoko L, Ahmed Shozib I. The Effect of Welding Current and Electrode Force on the Heat Input, Weld Diameter, and Physical and Mechanical Properties of SS316L/Ti6Al4V Dissimilar Resistance Spot Welding with Aluminum Interlayer. Materials. 2021; 14(5):1129. https://doi.org/10.3390/ma14051129
Chicago/Turabian StyleTaufiqurrahman, Iqbal, Azlan Ahmad, Mazli Mustapha, Turnad Lenggo Ginta, Luthfi Ady Farizan Haryoko, and Imtiaz Ahmed Shozib. 2021. "The Effect of Welding Current and Electrode Force on the Heat Input, Weld Diameter, and Physical and Mechanical Properties of SS316L/Ti6Al4V Dissimilar Resistance Spot Welding with Aluminum Interlayer" Materials 14, no. 5: 1129. https://doi.org/10.3390/ma14051129