| About this Abstract |
| Meeting |
2024 AWS Professional Program
|
| Symposium
|
2024 AWS Professional Program
|
| Presentation Title |
Mitigating Intermetallic Compound Formation of Al-Fe Resistance Spot Welding with Ultrasonic Welding of Interlayers |
| Author(s) |
Kaue Correa Riffel, Kelly Orsborn, Antonio J Ramirez, Rakhi Bawa |
| On-Site Speaker (Planned) |
Rakhi Bawa |
| Abstract Scope |
The use of aluminum in the automotive industry is of great interest as the demand for lightweighting and increased full economy continues to increase. Aluminum alloys are integrated into body-in-white designs with Advanced High Strength Steels (AHSS) to provide the optimum balance of lightweighting from aluminum and the high strength and crashworthiness provided by AHSS. However, joining these materials to Aluminum (Al) via Resistance Spot Welding (RSW) introduces challenges. When joining dissimilar materials like Al-AHSS, brittle intermetallic compounds form and compromise joint integrity and mechanical performance. Fe has limited solubility in Al and promotes the formation of FeAl3 and Fe2Al5 intermediate phases. Preliminary findings indicate that chromium mitigates the intermetallic layer and improves mechanical performance. 430 stainless steel interlayers measuring 250 µm thick are applied to the Al substrate via ultrasonic welding prior to joining to the AHSS. 430 stainless steel offers a high chromium content and has produced the best mechanical performance in prior testing. The ultrasonic welder has a tip with three unique knurling patterns, each of which are evaluated here to determine how the knurling pattern impacts the mechanical performance and intermetallic compound growth. |
| Proceedings Inclusion? |
Undecided |