Electron-Beam Welding Joint Strength of Dissimilar Materials

This paper provides an in-depth discussion of the joint strength of electron beam welding of dissimilar materials.The effect of welding parameters and material properties on the joint strength was analyzed,and an argument for the optimal parameter combination is presented.Electron-beam welding technology offers several advantages,including high energy density and the ability to create fine weld seams.However,it also presents certain challenges,such as the complexity of welding parameters and the potential generation of brittle phases.The analysis conducted in this paper holds significant importance in enhancing the quality and efficiency of dissimilar material welding processes.

SEMI-WEIGHT FUNCTION METHOD ON COMPUTATION OF STRESS INTENSITY FACTORS IN DISSIMILAR MATERIALS

Semi_weight function method is developed to solve the plane problem of two bonded dissimilar materials containing a crack along the bond. From equilibrium equation, stress and strain relationship, conditions of continuity across interface and free crack surface, the stress and displacement fields were obtained. The eigenvalue of these fields is lambda. Semi_weight functions were obtained as virtual displacement and stress fields with eigenvalue?_lambda. Integral expression of fracture parameters, K Ⅰ and K Ⅱ, were obtained from reciprocal work theorem with semi_weight functions and approximate displacement and stress values on any integral path around crack tip. The calculation results of applications show that the semi_weight function method is a simple, convenient and high precision calculation method.

Microstructure and mechanical properties of butt joints of QCr0.8/1Cr21Ni5Ti equal-thickness dissimilar materials by electron beam welding

Butt joints of QCr0.8/1Cr21Ni5Ti equal-thickness dissimilar materials were obtained by electron beam welding with fixed accelerating voltage 60 kV and focus current ~1.99 A , changed electron beam current and welding velocity. Microstructure and composition of the EBW joint were investigated by means of optical micrography and EDX analysis, mechanical properties of the joint were also tested. The results show that joint’s macrostructure was divided into three zones: top weld zone near QCr0.8 and bottom weld zone consisting of Cu(ss.Fe) with a certain amount of dispersedly distributed (α+ε) mixed microstructure, middle weld zone consisting of (α+ε) microstructure with a small amount of Cu(ss.Fe) particles. Morphological inhomogeneous macrostructure and uneven chemical compostion of QCr0.8/1Cr21Ni5Ti joint by EBW are the most important factor to result in decreasing joining strength.

A CRACK EMANATING FROM THE TIP OF BONDED DISSIMILAR MATERIALS

A crack is assumed to emanate from the tip of bonded dissimilar materials with the crack on the bisector of one of the bonded wedges. The problem is firstly divided into symmetric and anti-symmetric modes according to the characteristics of the local geometry. By eigenexpansion method, the eigenequations for the two modes are derived, respectively, and the corresponding eigenvalues are obtained with different ratios of dissimilar material constants and angles of the wedges. The singularity of the crack is then analyzed by the eigenvalues that are less than one. The fields of displacement and stress in the vicinity of the tip of the crack are finally derived in an explicit form.

WEIGHT FUNCTIONS FOR INTERFACE CRACKS IN DISSIMILAR ANISOTROPIC MATERIALS

Bueckner's work conjugate integral customarily adopted for linear elastic materials is established for an interface crack in dissimilar anisotropic materials.The difficulties in separating Stroh's six complex arguments involved in the integral for the dissimilar materials are overcome and thert the explicit function representations of the integral are given and studied in detail.It is found that the pseudo-orthogonal properties of the eigenfunction expansion form(EEF)for a crack presented previously in isotropic elastic cases,in isotopic bimaterial cases,and in orthotropic cases are also valid in the present dissimilar arbitrary anisotropic cases.The relation between Bueckner's work conjugate integral and the J-integral in these cases is obtained by introducing a complementary stress- displacement state.Finally,some useful path-independent integrals and weight functions are proposed for calculating the crack tip parameters such as the stress intensity factors.

A Novel Friction Stir Spot Riveting of Al/Cu Dissimilar Materials

In order to eliminate the disadvantages of the keyhole in conventional friction stir spot welding joint and attain the highstrength lap joint of Al/Cu dissimilar metals,a novel welding technique,named as friction stir spot riveting(FSSR),was proposed.A pinless tool and an extra filling stud were employed.The Al/Cu spot joints without keyhole defect were achieved by the FSSR.A Cu anchor-like structure was formed,which greatly increased the mechanical interlocking between the upper Al sheet and lower Cu sheet.The thin intermetallic compounds containing CuAl2 and CuAl at the Al/Cu interface strengthened the joining interface between the Al sheet and the Cu stud.Increasing rotating velocity increased frictional heat and plastic deformation and then eliminated the interfacial joining defects.The FSSR joint with the maximum tensile shear load of 3.50 kN was achieved at a rotating velocity of 1800 rpm and a dwell time of 20 s,whose fracture path passed through the softened region of upper Al sheet.In summary,the novel FSSR technique has the advantages of strong mechanical interlocking and metallurgical bonding between dissimilar materials,thereby attaining the high-strength spot joint.

Review on friction stir welding of dissimilar magnesium and aluminum alloys: Scientometric analysis and strategies for achieving high-quality joints

Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders progress in dissimilar Mg-Al joining is the formation of brittle intermetallic compounds(IMCs). As a solid-state joining technique, FSW is an excellent candidate to attenuate the deleterious IMC effects in dissimilar Al-Mg joining due to the inherent low heat inputs involved in the process. However, the IMCs, namely Al_(3)Mg_(2) and Al_(12)Mg_(17) phases, have also been reported to form during Al-Mg dissimilar FSW;their amount and thickness depend on the heat input involved;thus,the weld parameters used. Since the heat dissipated in the material during the welding process significantly affects the amount of IMCs,the heat input during FSW should be kept as low as possible to control and reduce the amount of IMCs. This review aims to critically discuss and evaluate the studies conducted in the dissimilar Al/Mg FSW through a scientometric analysis and also with a focus on the strategies recently applied to enhance joint quality. The scientometric analysis showed that the main research directions in Mg/Al FSW are the technological weldability of aluminum and magnesium during FSW, structural morphology, and mechanical properties of dissimilar welded joints. Considering the scope of application of the aforementioned joints, the low share of articles dealing with environmental degradation and operational cracking is surprising. This might be attributed to the need for well-developed strategies for obtaining high-quality and sustainable joints for applications. Thus, the second part of this review is conventional, focusing mainly on the new strategies for obtaining high-quality Mg/Al joints. It can be concluded that in addition to the necessity to optimum welding parameters to suppress the excessive heat to limit the amount and thickness of IMC formed and improve the overall joint quality, strategies such as using Zn interlayer, electric current assisted FSW(EAFSW), ultrasonic vibration FSW(UVa FSW), are considered effective in the elimination, reduction, and fragmentation of the brittle IMCs.

Interface microstructure and formation mechanism of ultrasonic spot welding for Al-Ti dissimilar metals

The present study focuses on interface microstructure and joint formation.AA6061 aluminum alloy(Al)and commercial pure titanium(Ti)joints were welded by ultrasonic spot welding(USW).The welding energy was 1100-3200 J.The Al-Ti joint appearance and interface microstructure were observed mainly via optical microscopy and field emission scanning electron microscopy.Results indicated that a good joint can be achieved only with proper welding energy of 2150 J.No significant intermetallic compound(IMC)was found under all conditions.The high energy barriers of Al-Ti and difficulties in diffusion were the main reasons for the absence of IMC according to kinetic analysis.The heat input is crucial for the material plastic flow and bonding area,which plays an important role in the joint formation.

Refill friction stir spot welding (RFSSW): a review of processing, similar/dissimilar materials joining, mechanical properties and fracture mechanism

Refill friction stir spot welding(RFSSW)provides a novel method to join similar and/or dissimilar metallic materials without a key-hole in the center of the joint.Having the key-hole free characterization,the similar/dissimilar RFSSW joint exhibits remarkable and endurable characteristics,including high shear strength,long fatigue life,and strong corrosion resistance.In the meanwhile,as the key-hole free joint has different microstructures compared with conventional friction stir spot welding,thus the RFSSW joint shall possess different shear and fatigue fracture mechanisms,which needs further investigation.To explore the underlying failure mechanism,the similar/dissimilar metallic material joining parameters and pre-treatment,mechanical properties,as well as fracture mechanisms under this novel technology will be discussed.In details,the welding tool design,welding parameters setting,and the influence of processing on the lap shear and fatigue properties,as well as the corrosion resistance will be mainly discussed.Moreover,the roadmap of RFFSW is also discussed.

A new model for predicting hydraulic fracture penetration or termination at an orthogonal interface between dissimilar formations

Vertical height growth of hydraulic fractures(HFs)can unexpectedly penetrate a stratigraphic interface and propagate into neighboring layers,thereby resulting in low gas-production efficiency and high risk of groundwater contamination or fault reactivation.Understanding of hydraulic fracture behavior at the interface is of pivotal importance for the successful development of layered reservoirs.In this paper,a twodimensional analytical model was developed to examine HF penetration and termination behavior at an orthogonal interface between two dissimilar materials.This model involves changes in the stress singularity ahead of the HF tip,which may alter at the formation interface due to material heterogeneity.Three critical stress conditions were considered to assess possible fracture behavior(i.e.,crossing,slippage,and opening)at the interface.Then,this model was verified by comparing its theoretical predictions to numerical simulations and three independent experiments.Good agreement with the simulation results and experimental data was observed,which shows the validity and reliability of this model.Finally,a parametric study was conducted to investigate the effects of key formation parameters(elastic modulus,Poisson’s ratio,and fracture toughness)between adjacent layers.These results indicate that the variation in the introduced parameters can limit or promote vertical HF growth by redistributing the induced normal and shear stresses at the interface.Among the three studied parameters,Poisson’s ratio has the least influence on the formation interface.When the fracture toughness and elastic modulus of the bounding layer are larger than those of the pay zone layer,the influence of fracture toughness will dominate the HF behavior at the interface;otherwise,the HF behavior will more likely be influenced by elastic modulus.

The Influence of Friction Time on the Joint Interface and Mechanical Properties in Dissimilar Friction Welds

The welding of dissimilar materials is one of the challenging issues in the fabrication industry to obtain required quality welds using fusion welding methods.However,some processes recently improved interface bonding with low joint strength.Unfortunately,the major intermetallic compounds could not alleviate from the joint interface.Alternatively,solid-state welding methods revealed fewer intermetallics at the joint interface for dissimilar material welds.Among them,friction welding was chosen to join incompatible materials with the necessary properties successfully.Friction time is a critical parameter for obtaining strong welds through friction welding,apart from friction pressure,forging pressure,forging time,and rotational speed.Variability of friction time can change the strength of friction by changing mechanical properties such as tensile strength.This change of tensile strength is typically influenced by the intermixing region,dependent on friction time.In this experiment,carbon steel and stainless steel have been friction welded to test the impact of friction time on the joint interface where the substrate’s faying surface meets.This interface consists of the intermixing region of the two materials on which the friction welding is performed.The results showed an interesting variation in tensile strength,with varying friction time.The width of the intermixing zone increased gradually with friction time until and decreased with the further increasing.The strength of the welds obtained was the highest of 730 MPa at a friction time of 4 s and fell as friction time’s increased value after 4 s.

Influence of Ni interlayer on interfacial microstructure and mechanical properties of Ti-6Al-4V/AZ91D bimetals fabricated by a solid–liquid compound casting process

The solid–liquid compound casting of Mg-AZ91D and Ti-TC4 alloys was developed by using pure Ni electro-deposited coating.The pouring temperatures of 660℃,690℃,720℃and 750℃were chosen to investigated the effects of casting temperatures on microstructural evolution,properties,and fracture behaviors of Ni-coated TC4/AZ91D bimetals by the solid–liquid compound casting(SLCC).The scanning electron microscopy(SEM)and the energy dispersive spectroscopy(EDS)results showed that the interfacial zone mainly composed of nickel,Mg_(2)Ni and Mg-Al-Ni in the bimetals cast at 660℃.As the pouring temperature was increased to 750℃,the width of the interface zone,which mainly composed ofδ(Mg),Mg_(2)Ni,Mg-Al-Ni,Mg_(3)TiNi_(2) and Al_(3)Ni,gradually increased.The microhardness tests showed that the micro-hardness of the interface zone was smaller than that of TC4 substrate but larger than that of the cast AZ91D matrix.At the pouring temperature of 720℃,the Ni-coated TC4/AZ91D bimetals had the most typical homogeneous interface,which had granular Mg-Al-Ni ternary phase but no ribbon-like Al3Ni binary phase,and achieved the highest shear strength of 97.35MPa.Meanwhile,further fracture behavior analysis showed that most fracture failure of Ni-coated TC4/AZ91D bimetals occurred at the Mg_(2)Ni+δ(Mg)eutectic structure and Al_(3)Ni hard intermetallic.

Evaluation of TiAl and 40Cr diffusion bonding quality using ultrasonic reflection spectrum

Combined with ultrasonic pulse-echo technique, reflection spectrum analysis was introduced to evaluate TiAl and 40Cr diffusion bonding quality. Frequency dependence of reflection coefficient was used to distinguish perfect bonding from imperfect bonding. It is found that the reflection coefficient from perfect bonding interface does not vary with frequency. When the size of imperfections is much smaller than the wavelength of ultrasound, the reflection coeffwient depends on frequency. When the size of imperfections is the same order of or even larger than the wavelength of ultrasound, the reflection coeffwient does not exhibit frequency dependence. However the amplitude of imperfect interface is higher than the amplitude of perfect bonding interface. A combination of reflection spectrum analysis and ultrasonic pulse-echo technique provides more accurate information about the bonding quality of dissimilar materials.

Effect of position and force tool control in friction stir welding of dissimilar aluminum-steel lap joints for automotive applications

Widespread use of aluminum alloys for the fabrication of car body parts is conditional to the use of appropriate welding methods,especially if dissimilar welding must be performed with automotive steel grades.Friction stir welding(FSW)is considered to be a reasonable solution to obtain sound aluminum-steel joints.In this context,this work studies the effects of tool position and force control in dissimilar friction stir welding of AA6061 aluminum alloy on DC05 low carbon steel in lap joint configuration,also assessing proper welding parameter settings.Naked eye and scanning electron microscopy(SEM)have been used to detect macroscopic and microscopic defects in joints,as well as to determine the type of intermixture between aluminum and steel.The joint strength of sound joints has been assessed by shear tension test.Results point out that tool force control allows for obtaining joints with better quality and strength in a wider range of process parameters.A process window has been determined for tool force conditions to have joints with adequate strength for automotive purposes.

Wire and arc additive manufacturing of dissimilar 2319 and 5B06 aluminum alloys

Aluminum alloy is the most widely used light alloy at present.By combining different types of aluminum alloys,their functional properties can be expanded.In the present research,two components composed of 2319(Al-6.5Cu)and 5B06(Al-6.4Mg)dissimilar alloys were fabricated by wire and arc additive manufacturing(WAAM).The deposited component with the bottom half of 2319 and the top half of 5B06 exhibits better mechanical properties than its counterpart deposited vice versa.Its ultimate tensile strength,yield strength,and elongation are 258.5 MPa,139.3 MPa,and 5.6%,respectively,which are only slightly inferior to the mechanical properties of 2319 base metal.The results show that for both components,fracture occurred at a layer thickness above the interface layer during the tensile test,regardless of the deposition order.It appears that the thermal stress due to the long dwell time and the remelting of the S-AlCu Mg phase are the main factors promoting crack initiation.Depending on the deposition order,cracks propagate either along the aggregated pores or stripθ-AlCu phase distributed along the grain boundary.By analyzing the heat input and selecting the appropriate depositing order,the strength of WAAM dissimilar aluminum alloys can be effectively improved through the proper control of microstructure and internal defects.

Time-dependent effects in transient liquid phase bonding of 304L and Cp-Ti using an Ag-Cu interlayer

One of the challenges for bimetal manufacturing is the joining process.Hence,transient liquid phase(TLP)bonding was performed between 304L stainless steel and Cp-Ti using an Ag-Cu interlayer with a thickness of 75μm for bonding time of 20,40,60,and 90 min.The bonding temperature of 860℃ was considered,which is under the β transus temperature of Cp-Ti.During TLP bonding,various intermetallic compounds(IMCs),including Ti_(5)Cr_(7)Fe_(17),(Cr,Fe)_(2)Ti,Ti(Cu,Fe),Ti_(2)(Cu,Ag),and Ti_(2)Cu from 304L toward Cp-Ti formed in the joint.Also,on the one side,with the increase in time,further diffusion of elements decreases the blocky IMCs such as Ti_(5)Cr_(7)Fe_(17),(Cr,Fe)_(2)Ti,Ti(Cu,Fe)in the 304L diffusion-affected zone(DAZ)and reaction zone,and on the other side,Ti_(2)(Cu,Ag)IMC transformed into fine morphology toward Cp-Ti DAZ.The microhardness test also demonstrated that the(Cr,Fe)_(2)Ti+Ti_(5)Cr_(7)Fe_(17) IMCs in the DAZ on the side of 304L have a hardness value of HV 564,making it the hardest phase.The maximum and minimum shear strength values are equal to 78.84 and 29.0 MPa,respectively.The cleavage pattern dominated fracture surfaces due to the formation of brittle phases in dissimilar joints.

Mechanical Performance Evaluation of Multi‑Point Clinch–Adhesive Joints of Aluminum Alloy A5052‑H34 and High‑Strength Steel JSC780

The clinch–adhesive process,which combines mechanical clinching and adhesive bonding,is one of the most applied pro-cesses for joining aluminum alloy and steel in the manufacturing of vehicle bodies.In this hybrid process,the clinching joints and adhesive bonds are coupled and influenced by each other,posing challenges to the process design and joining strength evaluation.To understand the influence of the clinching process on the performance of the adhesive layer,this study analyzes the mechanical behavior of clinch–adhesive joints between high-strength steel JSC780 and aluminum alloy A5052-H34 with different stack-up orientations and varying numbers of clinching points.The results reveal that,under the steel-on-top condition,the clinching process causes a discontinuous distribution of the adhesive layer,which significantly decreased the bonding strength.In contrast,under the aluminum-on-top condition,the clinching process has a lesser impact on the distribution of the adhesive layer,resulting in much higher strength than the steel-on-top condition.Simulation mod-els are constructed to quantify the effect of clinching points on the performance of the adhesive layer.The results highlight the need to consider diverse cohesive zone model parameters for the different stack orientations and clinching points in the design of clinch–adhesive aluminum alloy/steel structures.

A Study of Spot Welding of Advanced High Strength Steels for Automotive Applications

The application of advanced high strength steels in automotive industry has highlighted the need for research into spot weldability of these steels.Using weld lobe diagrams,the spot weldability of DP600 steel was found to be poor with conventional weld schedules.An enhanced weld schedule consisting of two pulses with reduced current on the second pulse gave a substantial increase in the lobe width;the first pulse removed the zinc coating and the second pulse controlled the nugget growth.A data acquisition system was designed to monitor weld expulsion during the weld operation.Of the three possible control strategies proposed,especially with AC welding equipment,the dynamic resistance signal is easily obtained and the least expensive.Expulsion phenomena,microstructural characterization and mechanical properties of spot-welded hot dipped galvanized DP600 steel and interstitial free steel were investigated.Further work on dissimilar welds in DP 600 and HSLA 350 was also conducted with emphasis on tensile and fatigue properties and fracture characteristics.The performance of dissimilar spot welds was different from that of the similar spot welds in each of the HSLA350 and DP600 steels.The DP600 weld properties played a dominating role in the hardness and tensile properties of the dissimilar spot welds.However,the fatigue performance of the dissimilar welds was similar to that of the HSLA welds.Details will be presented at the conference.

Additive manufacturing of copper-stainless steel hybrid components using laser-aided directed energy deposition

Combining dissimilar materials in a single component is an effective solution to integrate diverse material properties into a single part.Copper-stainless steel hybrid components are attracting more and more attention since the high thermal conductivity of copper can greatly enhance the thermal performance of stainless steel,which benefits its applications in many industries.However,direct joining of copper and stainless steel such as SS316 L is challenging since they preserve significant dissimilarities in physical,chemical,and thermo-mechanical properties.This paper aims to fabricate well-bonded copper-SS316 L hybrid parts using a laser-aided directed energy deposition(DED) process.A nickel-based alloy Deloro22(D22) is introduced between copper and SS316 L to address the detrimental issues in copper-SS316 L direct joints.Using this technique,defect-free interfaces are achieved at both the D22-SS316 L and copper-D22 transition zones.Tensile testing of Cu-D22-SS316 L and D22-SS316 L hybrid parts shows the fracture occurs at pure copper and SS316 L region,respectively,indicating an excellent bonding at the interfaces.Ascending in the building direction,a transition of grain structure is observed.A significant diffusion zone is obtained at both the D22-SS316 L and the Cu-D22 interfaces.The large diffusion distance results in a smooth variation in microhardness over the dissimilar materials.The microhardness increases from SS316 L to D22 with the highest value of 240 HV and then decreases from D22 to Cu with the lowest value of 63 ± 4 HV.Testing of thermophysical properties of the Cu-D22-SS316 L system indicates there is a ~300 % increase in thermal diffusivity and a ~200 % increase in thermal conductivity when compared to pure SS316 L.The significant increase in thermal diffusivity and conductivity validates the enhanced thermal performance of SS316 L when it is joined with pure copper.

Direct joining of oxygen-free copper and carbon-fiber-reinforced plastic by friction lap joining

Oxygen-flee copper （Cu） was successfully joined to carbon-fiber-reinforced thermoplastic （CFRTP, polyamide 6 with 20wt% carbon fiber addition） by friction lap joining （FLJ） at joining speeds of 200-1600 mm/min with a constant rotation rate of 1500 rpm and a nominal plunge depth of 0.9 ram. It is the first time to report the joining of CFRTP to Cu by FLJ. As the joining speed increased, the tensile shear force （TSF） of joints increased first, and decreased thereafter. The maximum TSF could reach 2.3 kN （ 15 mm in width）. Hydrogen bonding formed between the amide group of CFRTP and the thin Cu20 layer on the Cu surface, which mainly contributed to the joint bonding. The influence factors of the TSF of the joints at different joining speeds were discussed. The TSF was mainly affected by the joining area, the degradation of the plastic matrix and the number and the size of bubbles. As the joining speed increased, the influence factors varied as follows： the joining area increased first and then decreased; the degra- dation of the plastic matrix and the number and the size of bubbles decreased. The maximum TSF was the comprehensive result of the relatively large joining area, small degradation of the plastic matrix and small number and sizes of bubbles.