Dissimilar material joining using laser (aluminum to steel using zinc-based filler wire)

• Published in: Optics and laser technology Vol. 39; no. 3; pp. 652 - 661
• Main Authors: Mathieu, Alexandre, Shabadi, Rajashekar, Deschamps, Alexis, Suery, Michel, Matteï, Simone, Grevey, Dominique, Cicala, Eugen
• Format: Journal Article
• Language: English
• Published: Oxford Elsevier Ltd 01-04-2007; Elsevier Science; Elsevier
• Subjects: Aluminum; Biological and medical applications; Chemical and Process Engineering; Chemical Sciences; Cross-disciplinary physics: materials science; rheology; Engineering Sciences; Exact sciences and technology; Fundamental areas of phenomenology (including applications); Industrial applications; Laser beam joining; Material chemistry; Materials science; Materials synthesis; materials processing; Optics; Physics; Steel; Steel; Aluminum; Laser beam joining; Intermetallic compounds; Aluminium; Joining; Steels; Laser beam applications; Laser beams; Laser welding; Zinc; Aluminum: Steel
• ISSN: 0030-3992; 1879-2545
• DOI: 10.1016/j.optlastec.2005.08.014

Joining steel with aluminum involving the fusion of one or both materials is possible by laser beam welding technique. This paper describes a method, called laser braze welding, which is a suitable process to realize this structure. The main problem with thermal joining of steel/aluminum assembly with processes such as TIG or MIG is the formation of fragile intermetallic phases, which are detrimental to the mechanical performances of such joints. Braze welding permits a localized fusion of the materials resulting in a limitation on the growth of fragile phases. This article presents the results of a statistical approach for an overlap assembly configuration using a filler wire composed of 85% Zn and 15% Al. Tensile tests carried on these assemblies demonstrate a good performance of the joints. The fracture mechanisms of the joints are analyzed by a detailed characterization of the seams.