Advancements in Welding LIghtweight Metals to Steel

Joining lightweight metals to steel is becoming an increasingly important task as weight reduction requirements dictate new standards in many sheet metal assembly industries. The difference in the physical properties of steel and such materials as aluminum and magnesium makes joining them a difficult task. Resistance spot welding is the most preferred technology because it is easily automated. Direct welding of steel to other metals is not possible; for this reason different intermediate layers are suggested as mediators. Also, different ways of mediator layer deposition have been tried to minimize the number of additional operations. IDIR has developed a technology of joining light-weight metals to steel by cold-spraying the mediator layer onto the steel surface and resistance spot welding the metal sheets. The quality of the joint can be monitored by means of ultrasonic real-time inspection system. While operated in reflection mode, it can deliver information about the state of the faying interface between steel and other metal and characterize the quality of the joint.

References

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[2] Ranfeng Qiu, Chihiro Iwamoto, Shinobu Satonaka. "The influence of reaction layer on the strength of aluminum/steel joint welded by resistance spot welding." Materials Characterization 60, no. 2 (2009): 156-159.

[3] Masoumeh Pourali et. al, “Influence of welding parameters on intermetallic compounds formation in dissimilar steel/aluminum friction stir welds”, Journal of Alloys and Compounds, Volume 715, 25 August 2017, Pages 1–8

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[5] Honggang Dong et. al., “Dissimilar metal joining of aluminum alloy to galvanized steel with Al–Si, Al–Cu, Al–Si–Cu and Zn–Al filler wires”, Journal of Materials Processing Technology, V.212, Issue 2, February 2012, pp 458-464.

[6] W. Perez-Regalado, A. Ouellette, A.M. Chertov, V. Leshchynsky and R.Gr. Maev., “Joining Dissimilar Metals: A Novel Two Step Process with Ultrasonic Monitoring”, Materials Evaluation, July 2013, V. 71, No. 7.

[7] Paul Briskham, Nicholas Blundell, Li Han, Richard Hewitt, Ken Young, Douglas Boomer. "Comparison of Self-Pierce Riveting, Resistance Spot Welding and Spot Friction Joining for Aluminium Automotive Sheet." SAE 2006 World Congress & Exhibition. 2006

[8] Iwase Tetsu, Sasabe Seiji, Matsumoto Tsuyoshi, Tanigawa Masaki, Tawara Makoto, Pant Moka, Hattori Yasunori. "Dissimilar metal joining between aluminum alloy and hot-dip aluminunized steel sheet." Kobelco Technology Review, 2008: 29-34.

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[10] S. Agashe, H. Zhang. "Selection of schedules based on heat balance in resistance spot welding." Welding journal 82, no. 7 (2003).

[11] A.M. Chertov, R.Gr. Maev, Determination of Resistance Spot Weld Quality In Real Time Using Reflected Acoustic Waves. Comparison With Through-transmission Mode, 16th WCNDT 2004, Montreal, QC, Canada.

[12] A.C Karloff, A.M Chertov, J. Kocimski, P. Kustron, R. Gr. Maev, New Develpments for In situ Ultrasonic Measurement of Transient Temperature Distributions at the Tip of a Copper Resistance Spot Weld Electrode, IEEE International Ultrasonics Symposium (IUS) 2010.

[13] K. Mori, T. Kato, Y. Abe, Y. Ravshanbek,”Plastic Joining of Ultra High Strength Steel and Aluminium Alloy Sheets by Self Piercing Rivet”, CIRP Annals - Manufacturing Technology, Volume 55, Issue 1, 2006, Pages 283-286.

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