A Novel Bonding Method of Pure Aluminum and SUS304 Stainless Steel Using Barrel Nitriding
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INTRODUCTION
AUTOMOTIVE and aerospace industries have increasingly employed aluminum (Al) and Al alloys in manufacturing due to their light weight, high specific strength, good machinability, formability, and corrosion resistance compared to most steels.[1,2] With the increasing use of aluminum alloys to help reduce the vehicle weight and improve fuel efficiency,[3,4] there is an increasing need for dissimilar metal joining of Al to steel, which is still widely used in vehicles. It has been suggested that the joint between Al and steel can combine the advantages of the two materials and can have broad application prospects in the automotive, aerospace, shipbuilding, and other industries.[5–7] Most joining methods are preceded by brazing or welding process. For example, solid-state welding, such as friction welding, friction stir welding, roll welding, and ultrasonic welding, is used to weld Al to steel. These methods can produce high-quality joints,[8–13] but are often limited to special workpiece geometry, workpiece dimensions, joint designs, backing, etc. In addition, JUNG HYUN KONG, Postdoctoral Fellow, and MASAHIRO OKUMIYA and YOSHIKI TSUNEKAWA, Professors, are with the Toyota Technological Institute, 2-12-1, Hisakata, Tempaku, Nagoya 468-8511, Japan. Contact e-mail: [email protected]; kongja83 @gmail.com KY YOUL YUN, Assistant Professor, is with the Faculty of Engineering and Graduate School of Engineering, Gifu University, Gifu 501-1193, Japan. SANG GWEON KIM, Researcher, is with the Surface Technology & Heat Treatment R&D Department, Korea Institute of Industrial Technology 7-47, Songdo-Dong, Yeonsu-Gu, Incheon 406-840, South Korea. MASASHI YOSHIDA, Professor, is with the Department of Mechanical Engineering, Shizuoka Institute of Science and Technology, Hukuroi 437-8555, Japan. Manuscript submitted November 12, 2013. METALLURGICAL AND MATERIALS TRANSACTIONS A
these methods are generally accompanied by the degradation of the properties of the materials in the melting zone. Joining Al to steel is a great challenge because of the large differences in thermo-physical properties between the two materials,[14] and especially because of the strong tendency to form Fe-Al intermetallic compounds at elevated temperatures. The large differences between Al and steel in thermo-physical properties, such as melting point, thermal conductivity, and thermal expansion coefficient, can lead to high residual stresses in the resultant welds. In recent years, a new nitriding method using a barrel has been reported, which has the effect of the physical polishing of the surface for forming a nitride layer after the removal of the natural oxide film of aluminum.[15] In addition, a multilayer of AlN and Fe-Al could be formed at the interface between the aluminum and steel after barrel nitriding.[16] As is well known, AlN and Fe-Al intermetallic compounds are regarded as promising materials for industrial applications because of their excellent corrosion resistance, high wear resistance, and specific strength with high hardness va
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