Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging
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RESEARCH PAPER
Soldering of steel sheets and zinc-coated aluminum by hybrid composite forging T. Bick 1
&
K. Treutler 1 & V. Wesling 1
Received: 16 January 2019 / Accepted: 14 October 2020 # The Author(s) 2020
Abstract In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving, composite hybrid forging has been developed. In this process, an aluminum solid part and a steel sheet were formed in a single step and joined at the same time with zinc as brazing material. For this purpose, the zinc was applied by hot dipping on the aluminum in order to produce a Brazing via these layers in a forming process, under pressure and heat. Due to the formed intermediate layer of zinc, the formation of the Fe-Al intermetallic phases and the contact corrosion are excluded. By determining the mathematical relationships between joining parameters and the mechanical properties of the joint, the strength of a specific joint geometry could be adjusted to reach the level of conventional joining techniques. In addition to the presentation of the joint properties, the influence of the joining process on the structure of the involved materials will be shown. Furthermore, the failure behavior under static tensile and shear stress will be shown. Keywords Soldering . Aluminum . Steel . Hybrid composite forging
1 Introduction Lightweight construction is increasingly being built in multimaterial construction to save weight and resources. Especially in the car body, in addition to high-strength steels, light metals such as aluminum and magnesium are used. But aluminum and steel can only be joined together to a limited degree,
Recommended for publication by Commission XVII - Brazing, Soldering and Diffusion Bonding * T. Bick [email protected] K. Treutler [email protected] V. Wesling [email protected] 1
Institute of Welding and Machining, Clausthal University of Technology, Agricolastrasse 2, 38678 Clausthal-Zellerfeld, Germany
because in molten state, brittle intermetallic phases are formed, which can reach up to 1100 HV [1, 2]. Meco et al. investigated the influence of the intermetallic phases and the width of the heat-affected zone as a function of the temperature during the laser beam welding of aluminum and steel [3]. They showed that a narrow heat-affected zone with a low proportion of intermetallic phases is as damaging to the strength as large distinct phases themselves [4, 5]. Kashani et al. showed that the strength of laser overlap welded joints increases when the size of the intermetallic phase seam is less than 10 μm [6]. Zhang et al. investigated the influence of a zinc layer between aluminum and steel by using friction stir welding [7]. It was found that the zinc from the coating of the steel sheet has a positive influence on the formation of t
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