Research Progress and Technology of Dissimilar Joining Between Aluminum and Steel
LI Yan1,2, HU Zhili1,2, YU Haiyang1,2, PANG Qiu3
1 Key Laboratory of Hyundai Auto Parts Technology, Hubei Province, Wuhan 430070, China 2 Collaborative Innovation Center of Auto Parts Technology, Hubei Province, Wuhan 430070, China 3 School of Mechanical and Electrical Engineering, Wuhan Donghu University, Wuhan 430212, China
Abstract: Under the environment of rapid industrial development and energy saving and emission reduction, various industries have increasingly higher requirements on material performance. Therefore, heterogeneous metal structures with more comprehensive performance have attracted attention in recent years focus. The steel-aluminum hybrid structure has been widely used in plenty of industries including aerospace and vehicles because of its functional and economic advantages. For the automotive industry, lightweight is an inevitable trend for future development, and the application of steel-aluminum hybrid bodies is the most direct and effective way to reduce body-in-white weight. At the same time, the emergence of hybrid bodies also puts forward new requirements for the steel-aluminum joining process. There are four types joining processes of steel and aluminum include: fusion welding, brazing, mechanical joining and solid state joining. Difference between steel and aluminum in physical and chemical properties including melting point, thermal conductivity, ductility, and density makes it hard to join them together. The fusion welding process joint has high strength, but the welding process will produce intermetallic compounds that reduce the strength of the joint; the brazing process joint has high strength, good flatness, and strong controllability of welding para-meters, but it requires more cleanliness of the plate and has welding defects; the mechanical connection process is simple and its joint strength can be guaranteed, but the airtightness of the joint cannot be guaranteed; the solid state joining joint has high strength, but is limited by size and expensive price. In order to improve the quality of steel and aluminum joining joints, there are four main research directions currently: (1) optimization of existing process parameters; (2) plate pretreatment; (3) adjustment of plate position layout and new technology; (4) compound innovation of existing technology. According to a large number of studies of domestic and foreign researchers on the steel-aluminum joint process, it can be found that: (1) by controlling the experimental parameters, the optimal joint can be obtained under different experimental conditions and joining processes. (2) Pretreatment methods such as pre-coating Al layer or Zn layer on the steel plate makes it easier to join. (3) The relative position of the steel plate and the aluminum plate in the mechanical joining process and the solid state joining process will affect the quality of the joint. For some joining technologies, the addition of new elements such as ultrasonic generator and Zn foil can also optimize joint quality. (4) The quality of composite process joints is significantly better than single process joints, such as SPR + RSW (self-piercing riveting + resistance spot welding), FSW+CMT (friction stir welding + cold metal transition arc welding) and other composite process joints. This article reviews the four types existing joining process between steel and aluminum, mainly involving the basic principles of the process, technical advantages and disadvantages, joint performance, process essentials, and application occasions. At the same time, the domestic and foreign research status are summarized, including process parameters, material types and sizes, joint performance and morphology, conclusions and experimental data. Finally, the development direction of steel-aluminum joining process is prospected, which can provide a reference for the design and manufacture of steel and aluminum hybrid body.
李岩, 胡志力, 于海洋, 庞秋. 铝与钢异种材料连接技术及其研究进展[J]. 材料导报, 2020, 34(13): 13167-13174.
LI Yan, HU Zhili, YU Haiyang, PANG Qiu. Research Progress and Technology of Dissimilar Joining Between Aluminum and Steel. Materials Reports, 2020, 34(13): 13167-13174.
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2020, Vol. 34 
