Abstract
This paper presents microstructure and mechanical properties of deep penetration laser welding joints with/without Mn, Zr, or Sn powder in an overlap steel-on-aluminum configuration. Heats of formation, elastic modulus, and thermodynamic properties of intermetallic phases (IMCs) formed in joining steel to aluminum are determined by the use of first-principle calculation. A good agreement between the experimental results and theoretical predictions can be seen. In the case of adding Sn powder, no obvious porosity, cracks, and other defects are seen, and the layer thickness of IMCs is smallest among all the powders. In addition, the FeSn phase is formed at the steel/aluminum interface, the structure of FeSn is more stable than that of FeAl, and the ductility of FeSn is also better than that of FeAl; hence, mechanical properties of the welding joint are significantly improved.
Similar content being viewed by others
References
Sierra G, Wattrisse B, Bordreuil C (2008) Structural analysis of steel to aluminum welded overlap joint by digital image correlation. Exp Mech 48:212–223
Sierra G, Preyre P, Deschaux-Beaume F, Stuart D, Fras G (2007) Steel to aluminum key-hole laser welding. Mater Sci Eng A 447(1–2):197–208
Torkamany MJ, Tahamtan S, Sabbaghzadeh J (2010) Dissimilar welding of carbon steel to 5754 aluminum alloy by Nd:YAG pulsed laser. Mater Des 31(1–2):458–465
Ma K, Chen SH, Huang JH, Xia J, Zhang H, Zhao XK (2010) Microstructures and mechanical property of stainless steel/aluminum dissimilar alloy joint by laser key hole welding. Applied Lasers 30(6):493–497
Peng L, Zhou DW, Wu P, Zhang Y, Chen GY (2011) Laser lap welding of zinc-coated steel and 6016 aluminum alloy with Pb interlayer. Transactions of the China Welding Institution 32(12):81–84
Chen SH, Huang JH, Yang DD, Ma K, Zhang H (2012) Influence of Ni-foil interlayer on laser penetration welding of stainless steel to aluminum alloy. Transactions of the China Welding Institution 33(8):9–12
Yang XD, Shi Y, Liu J (2014) Effect of Cu foil on laser butt welding quality of aluminum/steel dissimilar metals joint. Journal of Mechanical Engineering 50(14):143–149
Kresse G, Furthmuller J (1996) Efficiency of ab-initio total energy calculations for metals and semiconductors using a plane-wave basis set. Comput Mater Sci 6(1):15–50
Lindan PLD, Segall MD, Probert MJ, Hasnip PJ, Clark SJ, Payne MC (2002) First principles simulation: ideas, illustrations and the CASTEP code. J Phys Condens Matter 14:2717–2743
Marlo M, Milman V (2000) Density-functional study of bulk and surface properties of titanium nitride using different exchange-correlation functionals. Phys Rev B 62:2899–2907
White JA, Bird DM (1994) Implementation of gradient-corrected exchange-correlation potentials in Car-Parrinello total-energy calculations. Phys Rev B 50:4954–4957
Vanderbilt D (1990) Soft self-consistent pseudopotentia1s in a generalized eigenvalue formalism. Phys Rev B 41:7892–7895
Perdew JP, Chevary JA, Vosko SH, Jaskson KA, Pederson MP, Singh DJ, Fiolhais C (1992) Atoms, molecules solids, and surfaces: applications of the generalized gradient approximation for exchange and correlation. Phys Rev B 46:6671–6687
Francis GP, Payne MC (1990) Finite basis set corrections to total energy pseudopotentia1 calculations. J Phys Condens Matter 2:4395–4404
Hammer B, Hansen LB, Norkov JK (1999) Improved adsorption energetics within density-functional theory using revised Perdew-Burke-Ernzerhof functionals. Phys Rev B 59:7413–7421
Monkhorst HJ, Pack JD (1976) Special points for Brillouin-zone integrations. Phys Rev B 13:5188–5192
Tang M. The structure and properties of Fe based alloy from first-principle calculation[D]. Nangning, Guangxi university; 2009
Feutelais Y, Legendre B, Guymont M, Ochin P (2001) Standard enthalpy of formation of Al0.28Fe0.72 at 298 K. J Alloys Compd 322(1):184–189
Simmous G, Wang H (1971) Single crystal elastic constants and calculated aggregate properties. M.I.T. Press, Cambridge
Vailhé C, Farkas D (1997) Shear faults and dislocation core structure simulations in B2 FeAl. Acta Mater 45(11):4463–4473
Wand YH, Liu YX, Zheng JG, Zhen ZN (2008) Construction and application of Finnis-Sinclair many-body potential for FeAl alloy. Journal of Shenyang Normal University (Natural Science) 26(3):290–296
Shu XL, Hu WY, Xiao HN, Zhang BW, Deng HQ (2001) Vacancies and antisites in B2 FeA1 and DO3 Fe3A1 with a modified analytic EAM model. J Mater Sci Technol 17(6):601–604
Kong Y, Hu WY, Huang YC, Shu XL (2003) Lattice dynamical study of B2 FeAl alloy by using the embedded atom method. Rare Metal Mater Eng 32(2):87–92
Summer A, Smith JF (1962) Elastic constants of single-crystal CaMg2. J Appl Phys 33(7):2283–2286
Mattesini M, Ahuja R, Johansson B (2003) Cubic Hf3N4 and Zr3N4: a class of hard materials. Phys Rev B 68(18):184108–184112
Yu WY, Wang N, Xiao XB, Tang BY, Peng LM, Ding WJ (2009) First-principles investigation of the binary AB2 type Laves phase in Mg-Al-Ca alloy: electronic structure and elastic properties. Solid State Sci 11(8):1400–1407
Pough SF (1954) Relations between the elastic moduli and the plastic properties of polycrystalline pure metals. Philos Mag 45:823–843
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhou, D., Xu, S., Zhang, L. et al. Microstructure, mechanical properties, and electronic simulations of steel/aluminum alloy joint during deep penetration laser welding. Int J Adv Manuf Technol 89, 377–387 (2017). https://doi.org/10.1007/s00170-016-9114-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9114-2