Deformation behavior of steel-to-aluminum tailor blanks made by laser/MIG hybrid and cold metal transfer brazing methods
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ORIGINAL ARTICLE
Deformation behavior of steel-to-aluminum tailor blanks made by laser/MIG hybrid and cold metal transfer brazing methods M. A. Shaker1 · M. K. Jain1 · J. Z. Chen2 Received: 24 April 2020 / Accepted: 25 August 2020 / Published online: 19 September 2020 © The Author(s) 2020
Abstract In this paper, dual phase steel (DP780) and AA2024-T3 aluminum sheets were successfully butt-welded together utilizing laser/MIG hybrid and cold metal transfer (CMT) brazing methods. A comparative study was conducted between the brazed joints produced by both methods in terms of wetting length, intermetallic compounds (IMCs) layer thickness, fracture position, and fracture mode. The results of testing showed that the produced joints from each method introduced significantly different deformation behavior. In addition, better wetting length and lower IMCs layer thickness are not the only factors that improve the mechanical behavior of brazed joints. The susceptibility of the aluminum base metal and time of exposure to the heat sources during joining process are also important. Keywords Steel/aluminum joints · Laser/MIG · Hybrid brazing · CMT brazing · Miniature tensile test
1 Introduction With greater emphasis on environmental regulations and fuel efficiency, lightweight metal alloys such as aluminum alloys are being increasingly utilized in fabricating automotive, aerospace, and other body structures and skin panels. Low density, high specific strength, good workability, superior corrosion resistance, dimensional stability, and recyclability make these lightweight metal alloys the preferred choice for many applications [17]. Therefore, many conventional all-steel body structures nowadays are being considered for replacement with hybrid steel and aluminum parts, thus requiring the development of technologies for joining of aluminum to steel [24]. Tailored blanks (TBs) made from joining steel and aluminum sheets for subsequent shaping M. A. Shaker
[email protected] M. K. Jain [email protected] J. Z. Chen [email protected] 1
Department of Mechanical Engineering, McMaster University, 1280 Main St. West, Hamilton, ON, L8S 4L7, Canada
2
CanmetMATERIALS, Natural Resources Canada, 183 Longwood Rd S, Hamilton, ON, L8P 0A5, Canada
are of much interest to the manufacturing industry. Such a combination, if properly joined, can provide benefit from higher structural rigidity of steels and the lightweight of aluminum. In the last two decades or so, steel/aluminum TBs are being increasingly used or considered for current and future applications such as automotive and aerospace constructions as they offer attractive combination of strength and performance in applications where weight reduction is desirable. For example, by 2025 in North America, 16% of all the body structure and closure parts, on a volume basis, for light vehicles will be made of aluminum sheets. This means, aluminum sheets for light vehicle bodies and closure parts will grow from less than 1 billion pounds in 2015 to nearly 4 billion pounds by 2025 [3].
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