Interfacial bonding mechanism in Al/coated steel dissimilar refill friction stir spot welds
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Defect-free dissimilar Al/zinc coated steel and Al/AlSi coated steel welds were successfully fabricated by refill friction stir spot welding. However, Al alloy and uncoated steel could not be welded under the same welding condition. Al-Zn eutectic layer formed at the Al/zinc coated steel interface showed non-uniformity in thickness and nanoscale intermetallic (IMC) produced was discontinuous. The bonding formation between the Al-Zn layer and the surrounding materials was attributed to a liquid/solid reaction mechanism. Bonding formation at Al alloy and AlSi coated steel interface was attributed to a solid/solid reaction mechanism, as the joining process did not involve with melting of base metals or AlSi coating materials. Kissing bond formed at the weld boundary acted as a crack initiation and propagation site, and the present study showed that weld strength of Al 5754/AlSi coated steel was greatly influenced by properties of original IMC layer.
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Z. Shen, Y. Ding, J. Chen, B. Shalchi Amirkhiz, John Z. Wen, L. Fu, Adrian P. Gerlich (2019). Interfacial bonding mechanism in Al/coated steel dissimilar refill friction stir spot welds. UWSpace. http://hdl.handle.net/10012/14668
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