| METALS AND METAL MATRIX COMPOSITES |
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| Research Progress of Resistance Spot Welding of Aluminum/Steel Dissimilar Metals |
| CHEN Yajun1,*, LI Siwei2, MENG Xianming3, SHI Liting3, XIAO Zewen2
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1 Sino-European Institute of Aviation Engineering, Civil Aviation University of China, Tianjin 300300, China
2 College of Aeronautical Engineering, Civil Aviation University of China, Tianjin 300300, China
3 CATARC (Tianjin) Automotive Engineering Research Institute Co., Ltd., Tianjin 300300, China |
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Abstract Aluminum/steel resistance spot welding (RSW) is an important technology to promote the application of lightweight materials in automotive industries. However, aluminum alloys and steels are significantly different with each other in thermal conductivity, electrical conductivity and thermal expansion. Moreover, a brittle layer of Al-Fe intermetallic compound (IMC) is prone to form at the Al/steel faying interface. These disadvantages make it quite challenging to obtain sound welding joints between aluminum alloys and steels. In recent years, the improved design of electrodes have enhanced the welding performance of Al/steel RSW, which combined with the process optimization leads to achieving acceptable quality of Al/steel RSW. Researchers revealed the growth mechanism of IMC and the fracture failure mechanism of aluminum/steel RSW joints. The influence of IMC thickness, weld nugget diameter, the steel coating types, welding production conditions and corrosion on the quality of aluminum/steel RSW joints were studied in detail. Various methods have also been proposed to improve the welding quality, such as optimizing the welding parameters, employing the cover plate or interlayer and hybrid welding, which ultimately guide the design of welding process and promote the application of aluminum/steel RSW in automotive industries. This contribution gives a review of the global research in Al/steel dissimilar RSW. It mainly focuses on the micro-level causal occurrences of IMC growth, fracture behavior of welded joints, factors influencing welding quality, process optimization methods, and simulation analysis of welding.
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Published:
Online: 2023-07-10
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| Fund:National Natural Science Foundation of China (11972364) and China Postdoctoral Science Foundation (2021M693472). |
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2023, Vol. 37 
