Hierarchical Morphology and Formation Mechanism of Collision Surface of Al/Steel Dissimilar Lap Joints via Electromagnetic Pulse Welding
Abstract
:1. Introduction
2. Materials and Methods
3. Results
3.1. Local Impact Characteristics in Layer I
3.2. Dimple Feature in Layer II
3.3. Shear Plateau in Layer III
3.4. Local Melting and Porous Structure in Layer IV
3.5. Concave and Convex Morphology in Layer V
4. Discussion
4.1. Microstructural Evolution and Formation Mechanism
4.2. Effect of Impact Parameters on Interfacial Characteristics
5. Conclusions
- (1)
- During EMPW, a strong electromagnetic force propelled the Al sheet, hitting the steel sheet at a high velocity and creating a robust dissimilar lap joint with a special collision surface containing multi-zones. Based on the interfacial microstructure and bonding state, the collision surface was defined as the central non-weld zone, welding-affected zone, secondary weld zone, primary weld zone, and impact-affected zone from the center to outside.
- (2)
- The central non-weld zone exhibited a concave and convex morphology. The welding-affected zone mainly included some melting features and porous structures, representing a porous joining. The secondary weld zone presented an obvious mechanical joining characterized by the shear plateaus with stripes, and the instantaneous melting and rapid solidification features were prone to cracking due to the presence of residual stresses. The primary weld zone, characterized by dimples with cavity features, indicated the formation of diffusion or metallurgical bonding. The impact-affected zone denoted an invalid interfacial bonding due to the discontinuous spot impact.
- (3)
- The impact energy and pressure influenced the changes of normal velocity and tangential velocity, and in turn, affected the interfacial deformation behavior and bonding characteristics, including the formation of micropores, which continued to grow into homogeneous or uneven porous structures under cavitation, surface tension, and depressurization, along with the effect of trapped air.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Material | Mg | Si | Cu | Mn | Fe | Zn | Ti | Cr | Ni | Al |
---|---|---|---|---|---|---|---|---|---|---|
6061 O-Al alloy | 1.0 | 0.7 | 0.3 | 0.15 | 0.2 | 0.25 | 0.03 | 0.15 | 0.05 | Bal |
Material | C | Si | Mn | P | S | Cr | Ni | Cu | N | Fe |
---|---|---|---|---|---|---|---|---|---|---|
Q355B | 0.24 | 0.55 | 1.6 | 0.035 | 0.035 | 0.3 | 0.3 | 0.4 | 0.012 | Bal |
V (Non-Weld Zone) | IV (Welding Affected Zone) | III (Secondary Weld Zone) | II (Primary Weld Zone) | I (Impact Affected Zone) | |
---|---|---|---|---|---|
Impact energy | E5 | E4 | E3 | E2 | E1 |
Collision angle | |||||
Impact velocity | |||||
Pressure | P5 | P4 | P3 | P2 | P1 |
Pore or cavity | Continuous impact | Air compression + Local impact | |||
Bonding state | Unbonded | Porous joining | Mechanical joining | Diffusion or metallurgical bonding | Spot joining |
Fracture location | Non | Less |
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Wang, P.; Chen, D.; Yan, Y.; She, X.; Feng, B.; Ran, Y.; Peng, H.; Li, D.; Jiang, X. Hierarchical Morphology and Formation Mechanism of Collision Surface of Al/Steel Dissimilar Lap Joints via Electromagnetic Pulse Welding. Metals 2021, 11, 1468. https://doi.org/10.3390/met11091468
Wang P, Chen D, Yan Y, She X, Feng B, Ran Y, Peng H, Li D, Jiang X. Hierarchical Morphology and Formation Mechanism of Collision Surface of Al/Steel Dissimilar Lap Joints via Electromagnetic Pulse Welding. Metals. 2021; 11(9):1468. https://doi.org/10.3390/met11091468
Chicago/Turabian StyleWang, Puquan, Daolun Chen, Yunqi Yan, Xinwei She, Bo Feng, Yang Ran, He Peng, Dongyang Li, and Xianquan Jiang. 2021. "Hierarchical Morphology and Formation Mechanism of Collision Surface of Al/Steel Dissimilar Lap Joints via Electromagnetic Pulse Welding" Metals 11, no. 9: 1468. https://doi.org/10.3390/met11091468