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Joining Dissimilar Metals: A Novel Two-step Process with Ultrasonic Monitoring

This paper presents a current development on the resistance spot welding methodology to join aluminum alloys to mild steels. A novel two-step welding process with ultrasonic monitoring is proposed. The technique is based on the usage of an intermediate layer made by cold spray to avoid the formation of brittle intermetallics between Al and Fe. The morphology and growth of intermetallic compounds that are formed on the interface of steel and molten aluminum during nugget formation were investigated by in-situ ultrasonic monitoring, and also using SEM and EDAX spectroscopy

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