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Interfacial Microstructure and Strength of Aluminum to Steel Joints made by Pulsed Gas Metal Arc Spot Welding-Brazing Process
Light weight multi-material designs, involving high performance Al alloys and advanced high strength steels, are now considered to be one of the best approaches for reducing the weight of automotive body structures. A new spot welding-brazing hybrid process using pulsed gas metal arc welding with Al 4047 filler wire was developed to join Zn-coated sheet to aluminum alloy in this work. The effect of heat input on tensile-share strength of spot weld joint was investigated. The interfacial microstructure between steel and Al 4047 liquid filler metal was characterized by scanning electron microscope (SEM) equipped with an EDAX energy dispersive X-ray (EDX) analyser as well as transmission electron microscopy (TEM). The results showed that an ultra-thin intermetallic phase (IMP) layer was formed at the interface, which resulted in a high joint strength between steel and aluminum. The joint formation mechanism was discussed.
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