Welding of Dissimilar Steel/Al Joints Using Dual-Beam Lasers with Side-by-Side Configuration
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
3.1. Weld Shape of the Steel/Al Joints
3.1.1. Effect of the Dual-Beam Power Ratio (Rs)
3.1.2. Effect of the Dual-Beam Distance (d1)
3.2. Microstructures of the Al/Weld Interface
3.2.1. Morphology and Thickness
3.2.2. Phase Identification
3.2.3. Grain Shape and Grain Size
3.3. Tensile Resistance of the Steel/Al Joints
4. Conclusions
- (1)
- Soundly welded steel/Al lapped joints free of welding defects have been successfully achieved by using dual-beam laser welding with side-by-side configuration. The processing parameters of Rs and d1 have a great influence on the weld appearance, the P2 and the welding defects. The good weld shape should be obtained at the relatively equal Rs of 0.50, 0.67 and 1.50 during side-by-side dual-beam laser welding of the steel/Al joints. The optimum d1 for obtaining good weld shape is limited to 0.5 mm and 1.0 mm for side-by-side dual-beam laser welding of the steel/Al joints.
- (2)
- The Al/weld interface microstructure in different locations consists of the island-shape structures and lath-like layer; however, the morphology and the lath-like layer thickness are different in each zone. The P2 has a significant influence on the morphology and the lath-like layer thickness, and controlling the P2 is effective to inhibit the formation of IMC layers at the Al/weld interface.
- (3)
- EBSD phase mapping proves that the microstructures at the Al/weld interface are composed of the η-Fe2Al5 layers and the θ-Fe4Al13 phases, and very fine θ-Fe4Al13 and η-Fe2Al5 phases are formed along α-Fe grain boundary inside the weld of the steel/Al joints. The η-Fe2Al5 layers and the needle-like θ-Fe4Al13 grains formed at the Al/weld interface are finer than those of the weld and the Al alloy.
- (4)
- There is a matching relationship between the P2 and the tensile resistance of steel/Al joints produced by dual-beam laser welding with side-by-side configuration, and the maximum tensile resistance of the steel/Al joints is obtained at the Rs of 1.50 during dual-beam laser welding with side-by-side configuration.
- (5)
- Two different fracture propagation paths are found depending on the P2. The fracture profile of the steel/Al joints with an optimized P2 exhibits a ductile fracture occurring in the parent metal or seam, resulting in a relatively high tensile resistance of the steel/Al joints.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
- Sun, Z.; Ion, J.C. Review laser welding of dissimilar metal combinations. J. Mater. Sci. 1995, 30, 4205–4214. [Google Scholar] [CrossRef]
- Shah, L.H.; Ishak, M. Review of research progress on aluminum–steel dissimilar welding. Mater. Manuf. Process. 2014, 29, 928–933. [Google Scholar] [CrossRef]
- Shao, L.; Shi, Y.; Huang, J.K.; Wu, S.J. Effect of joining parameters on microstructure of dissimilar metal joints between aluminum and galvanized steel. Mater. Des. 2015, 66, 453–458. [Google Scholar] [CrossRef]
- Song, J.L.; Lin, S.B.; Yang, C.L.; Ma, G.C.; Liu, H. Spreading behavior and microstructure characteristics of dissimilar metals TIG welding–brazing of aluminum alloy to stainless steel. Mater. Sci. Eng. A 2009, 509, 31–40. [Google Scholar] [CrossRef]
- Katayama, S. Laser welding of aluminium alloys and dissimilar metals. Weld Int. 2004, 18, 618–625. [Google Scholar] [CrossRef]
- Meco, S.; Pardal, G.; Ganguly, S.; Williams, S.; Mcpherson, N. Application of laser in seam welding of dissimilar steel to aluminium joints for thick structural components. Opt. Laser Eng. 2015, 67, 22–30. [Google Scholar] [CrossRef] [Green Version]
- Corigliano, P.; Crupi, V.; Guglielmino, E.; Sili, A.M. Full-field analysis of Al/Fe explosive welded joints for shipbuilding applications. Mar. Struct. 2018, 57, 207–218. [Google Scholar] [CrossRef]
- Corigliano, P.; Crupi, V.; Guglielmino, E. Non linear finite element simulation of explosive welded joints of dissimilar metals for shipbuilding applications. Ocean Eng. 2018, 160, 346–353. [Google Scholar] [CrossRef]
- Kaya, Y. Microstructural, mechanical and corrosion investigations of ship steel-aluminum bimetal composites produced by explosive welding. Metals 2018, 8, 544. [Google Scholar] [CrossRef]
- Findik, F. Recent developments in explosive welding. Mater. Des. 2011, 32, 1081–1093. [Google Scholar] [CrossRef]
- Xie, M.X.; Shang, X.T.; Zhang, L.J.; Bai, Q.L.; Xu, T.T. Interface characteristic of explosive-welded and hot-rolled TA1/X65 bimetallic plate. Metals 2018, 8, 159. [Google Scholar] [CrossRef]
- Topolski, K.; Szulc, Z.; Garbacz, H. Microstructure and properties of the Ti6Al4V/Inconel 625 bimetal obtained by explosive joining. J. Mater. Eng. Perform. 2016, 25, 3231–3237. [Google Scholar] [CrossRef]
- Borrisutthekul, R.; Yachi, T.; Miyashita, Y.; Mutoh, Y. Suppression of intermetallic reaction layer formation by controlling heat flow in dissimilar joining of steel and aluminum alloy. Mater. Sci. Eng. A 2007, 467, 108–113. [Google Scholar] [CrossRef]
- Gao, M.; Chen, C.; Mei, S.W.; Wang, L.; Zeng, X.Y. Parameter optimization and mechanism of laser-arc hybrid welding of dissimilar Al alloy and stainless steel. Int. J. Adv. Manuf. Technol. 2014, 74, 199–208. [Google Scholar] [CrossRef]
- Bouche, K.; Barbier, F.; Coulet, A. Intermetallic compound layer growth between solid iron and molten aluminium. Mater. Sci. Eng. A 1998, 249, 167–175. [Google Scholar] [CrossRef]
- Wang, P.F.; Chen, X.Z.; Pan, Q.H.; Madigan, B.; Long, J.Q. Laser welding dissimilar materials of aluminum to steel: an overview. Int. J. Adv. Manuf. Technol. 2016, 87, 3081–3090. [Google Scholar] [CrossRef]
- Chen, S.H.; Huang, J.H.; Ma, K.; Zhao, X.K.; Vivek, A. 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, 45A, 3064–3073. [Google Scholar] [CrossRef]
- Shabadi, R.; Suery, M.; Deschamps, A. Characterization of joints between aluminum and galvanized steel sheets. Metall. Mater. Trans. A 2013, 44A, 2672–2682. [Google Scholar] [CrossRef]
- Sun, J.H.; Yan, Q.; Gao, W. Investigation of laser welding on butt joints of Al/steel dissimilar materials. Mater. Des. 2015, 83, 120–128. [Google Scholar] [CrossRef]
- Dharmendra, C.; Rao, K.P.; Wilden, J.; Reich, S. Study on laser welding-brazing of zinc coated steel to aluminum alloy with a zinc based filler. Mater. Sci. Eng. A 2011, 528, 1498–1503. [Google Scholar] [CrossRef]
- Kouadri-David, A.; PSM Team. Study of metallurgic and mechanical properties of laser welded heterogeneous joints between DP600 galvanised steel and aluminium 6082. Mater. Des. 2014, 54, 184–195. [Google Scholar] [CrossRef]
- Li, L.Q.; Chen, Y.B.; Wang, T. Research on dual-beam welding characteristics of aluminum alloy. Chin. J. Lasers 2008, 35, 1784–1788. [Google Scholar] [CrossRef]
- Li, C.L.; Fan, D.; Wang, B. Characteristics of TIG arc-assisted laser welding-brazing joint of aluminum to galvanized steel with preset filler powder. Rare Met. 2015, 34, 650–656. [Google Scholar] [CrossRef]
- Sierra, G.; Peyre, P.; Deschaux-Beaume, F.; Stuart, D.; Fras, G. Steel to aluminum key-hole laser welding. Mater. Sci. Eng. A 2007, 447, 197–208. [Google Scholar] [CrossRef]
- Fabbro, R. Melt pool and keyhole behaviour analysis for deep penetration laser welding. J. Phys. D Appl. Phys. 2010, 43, 445–451. [Google Scholar] [CrossRef] [Green Version]
- Milberg, J.; Trautmann, A. Defect-free joining of zinc-coated steels by bifocal hybrid laser welding. Prod. Eng. Res. Dev. 2009, 3, 9–15. [Google Scholar] [CrossRef]
- Iwase, T.; Sakamoto, H.; Shibata, K.; Hohenberger, B.; Dausinger, F. Dual-focus technique for high-power Nd:YAG laser welding of aluminum alloys. In SPIE High-Power Lasers in Manufacturing; Chen, X.L., Fujioka, T.M., Matsunawa, A., Eds.; Advanced High-Power Lasers and Applications: Osaka, Japan, 1999; pp. 348–358. [Google Scholar]
- Blackburn, J.E.; Allen, C.M.; Hilton, P.A.; Li, L. Dual focus Nd:YAG laser welding of titanium alloys. Lasers Eng. 2012, 22, 279–282. [Google Scholar]
- Gref, W.; Russ, A.; Leimser, M.; Dausinger, F.; Huegel, H. Double-focus technique: influence of focal distance and intensity distribution on the welding process. In First International Symposium on High-Power Laser Macroprocessing; LAMP: Osaka, Japan, 2002. [Google Scholar] [CrossRef]
- Ma, G.L.; Li, L.Q.; Chen, Y.B. Effects of beam configurations on wire melting and transfer behaviors in dual beam laser welding with filler wire. Opt. Laser Technol. 2017, 91, 138–148. [Google Scholar] [CrossRef]
- Hansen, K.S.; Olsen, F.O.; Kristiansen, M.; Madsen, O. Joining of multiple sheets in a butt-joint configuration using single pass laser welding with multiple spots. J. Laser Appl. 2015, 27. [Google Scholar] [CrossRef]
- Xie, J. Dual beam laser welding. Weld J. 2002, 81, 223–230. [Google Scholar]
- Hsu, R.; Engler, A.; Heinemann, S. The gap bridging capability in laser tailored blank welding. Laser Inst. Am. 1998, F224–F231. [Google Scholar] [CrossRef]
- Laukant, H.; Wallmann, C.; Korte, M.; Glatzel, U. Flux-less joining technique of aluminum with zinc-coated steel sheets by a dual-spot-laser beam. Adv. Mater. Res. 2005, 6–8, 163–170. [Google Scholar] [CrossRef]
- Shi, Y.; Zhang, H.; Takehiro, W.; Tang, J.G. CW/PW dual-beam YAG laser welding of steel/aluminum alloy sheets. Opt. Lasers Eng. 2010, 48, 732–736. [Google Scholar] [CrossRef]
- Chen, S.H.; Zhai, Z.L.; Huang, J.H.; Zhao, X.K.; Xiong, J.G. Interface microstructure and fracture behavior of single/dual-beam laser welded steel-Al dissimilar joint produced with copper interlayer. Int. J. Adv. Manuf. Technol. 2016, 82, 631–643. [Google Scholar] [CrossRef]
- Cui, L.; Chen, B.X.; Chen, L.; He, D.Y. Dual beam laser keyhole welding of steel/aluminum lapped joints. J. Mater. Process. Technol. 2018, 256, 87–97. [Google Scholar] [CrossRef]
- Mohammadpour, M.; Yazdian, N.; Yang, G.; Wang, H.P.; Carlson, B.; Kovacevic, R. Effect of dual laser beam on dissimilar welding-brazing of aluminum to galvanized steel. Opt. Laser Technol. 2018, 98, 214–228. [Google Scholar] [CrossRef]
- Xia, H.B.; Zhao, X.Y.; Tan, C.W.; Chen, B.; Song, X.G.; Li, L.Q. Effect of Si content on the interfacial reactions in laser welded-brazed Al/steel dissimilar butted joint. J. Mater. Process. Technol. 2018, 258, 9–21. [Google Scholar] [CrossRef]
- Springer, H.; Kostka, A.; Payton, E.J.; Raabe, D.; Kaysser-Pyzalla, A.; Eggeler, G. On the formation and growth of intermetallic phases during interdiffusion between low-carbon steel and aluminum alloys. Acta Mater. 2011, 59, 1586–1600. [Google Scholar] [CrossRef]
- Zhang, H.T.; Feng, J.C.; He, P.; Hackl, H. Interfacial microstructure and mechanical properties of aluminium-zinc-coated steel joints made by a modified metal inert gas welding-brazing process. Mater. Charact. 2007, 58, 588–592. [Google Scholar] [CrossRef]
- Balogh, Z.; Schmitz, G. Diffusion in Metals and Alloys; Laughlin, D.E., Hono, K., Eds.; Physical Metallurgy: Oxford, UK, 2014; pp. 387–559. [Google Scholar]
Materials | Mg | C | P | Ni | S | Mn | Cr | Fe | Si | Zn | Ti | Cu |
---|---|---|---|---|---|---|---|---|---|---|---|---|
6061 | 0.8–1.2 | - | - | - | - | ≤0.15 | 0.04–0.3 | ≤0.7 | 0.4–0.8 | ≤0.25 | ≤0.15 | 0.15–0.4 |
Q235 | - | ≤0.2 | ≤0.04 | ≤0.3 | ≤0.04 | 0.3–0.7 | ≤0.30 | Bal. | ≤0.35 | - | - | ≤0.30 |
© 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
Share and Cite
Cui, L.; Chen, H.; Chen, B.; He, D. Welding of Dissimilar Steel/Al Joints Using Dual-Beam Lasers with Side-by-Side Configuration. Metals 2018, 8, 1017. https://doi.org/10.3390/met8121017
Cui L, Chen H, Chen B, He D. Welding of Dissimilar Steel/Al Joints Using Dual-Beam Lasers with Side-by-Side Configuration. Metals. 2018; 8(12):1017. https://doi.org/10.3390/met8121017
Chicago/Turabian StyleCui, Li, Hongxi Chen, Boxu Chen, and Dingyong He. 2018. "Welding of Dissimilar Steel/Al Joints Using Dual-Beam Lasers with Side-by-Side Configuration" Metals 8, no. 12: 1017. https://doi.org/10.3390/met8121017