Numerical simulation on MIG arc brazing-fusion welding of aluminum alloy to galvanized steel plate

  • Guoliang Qin
  • Yuhu Su
  • Xiangmeng Meng
  • Banglong Fu


Based on the difference in melting point between aluminum alloy and steel, metal inert gas (MIG) arc brazing-fusion welding process was developed to join thin 6013 aluminum alloy plate to galvanized steel plate. A finite element model for lap joint was established to study its thermal process. In modeling, MIG arc was treated as the double ellipse Gaussian plane heat source and the overheated metal droplet was considered as the uniform body heat source. The effects of the zinc coating and the overlap gap were taken into consideration. The brazed seam width and the width of heat-affected zinc coating on the back side of galvanized steel plate were used to validate the calculated results. The results show that the calculated results are in good agreement with experimental results. The calculation results indicate that the temperature is not uniformly distributed in the brazing-fusion welded joint. There is a great difference in the reaction temperature and time at different positions on the brazed interface. In order to satisfy the energy condition in which aluminum plate is fully penetrated and steel plate is not melted, a corresponding relationship that the welding current and welding speed are synchronized to be increased must be followed.


Brazing-fusion welding Dissimilar joint Pulsed MIG welding Numerical simulation Finite element method Energy condition 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. 1.
    Elliott S, Wallach E (1981) Joining aluminum to steel. Pt. 2. Friction welding. Met Constr 13:221–225Google Scholar
  2. 2.
    Zhang H, Liu J (2011) Microstructure characteristics and mechanical property of aluminum alloy/stainless steel lap joints fabricated by MIG welding–brazing process. Mater Sci Eng A 528:6179–6185CrossRefGoogle Scholar
  3. 3.
    Jácome LA, Weber S, Leitner A, Arenholz E, Bruckner J, Hackl H, Pyzalla AR (2009) Influence of filler composition on the microstructure and mechanical properties of steel–aluminum joints produced by metal arc joining. Adv Eng Mater 11:350–358CrossRefGoogle Scholar
  4. 4.
    Zhang H, Feng J, He P, Hackl H (2007) Interfacial microstructure and mechanical properties of aluminium–zinc-coated steel joints made by a modified metal inert gas welding–brazing process. Mater Charact 58:588–592CrossRefGoogle Scholar
  5. 5.
    Dong H, Hu W, Duan Y, Wang X, Dong C (2012) Dissimilar metal joining of aluminum alloy to galvanized steel with Al–Si, Al–Cu, Al–Si–Cu and Zn–Al filler wires. J Mater Process Technol 212:458–464CrossRefGoogle Scholar
  6. 6.
    Murakami T, Nakata K, Hongjun T, Ushio M (2003) Dissimilar metal joining of aluminum to steel by MIG arc brazing using flux cored wire. ISIJ Int 43:1596–1602CrossRefGoogle Scholar
  7. 7.
    Dharmendra C, Rao K, Wilden J, Reich S (2011) Study on laser welding–brazing of zinc coated steel to aluminum alloy with a zinc based filler. Mater Sci Eng A 528:1497–1503CrossRefGoogle Scholar
  8. 8.
    Meco S, Pardal G, Ganguly S, Ganguly S, Miranda R, Quintino L, Williams S (2013) Overlap conduction laser welding of aluminium to steel. Int J Adv Manuf Technol 67:647–654CrossRefGoogle Scholar
  9. 9.
    Qin G, Lei Z, Su Y, Fu B, Meng X, Lin S (2014) Large spot laser assisted GMA brazing–fusion welding of aluminum alloy to galvanized steel. J Mater Process Technol 214:2684–2692CrossRefGoogle Scholar
  10. 10.
    Gao M, Chen C, Mei S, Wang L, Zeng X (2014) Parameter optimization and mechanism of laser–arc hybrid welding of dissimilar Al alloy and stainless steel. Int J Adv Manuf Technol 74:199–208CrossRefGoogle Scholar
  11. 11.
    Mathieu A, Matteï S, Deschamps A, Martin B, Grevey D (2006) Temperature control in laser brazing of a steel/aluminium assembly using thermographic measurements. NDT Int 39:272–276CrossRefGoogle Scholar
  12. 12.
    Peyre P, Sierra G, Deschaux-Beaume F, Stuart D, Fras G (2007) Generation of aluminium–steel joints with laser-induced reactive wetting. Mater Sci Eng A 444:327–338CrossRefGoogle Scholar
  13. 13.
    Park J, Na S (1998) Heat transfer in a stud-to-plate laser braze considering filler metal movement. Weld J 77:155–163Google Scholar
  14. 14.
    Jeon M-K, Kim W-B, Han G-C, Na S-J (1998) A study on heat flow and temperature monitoring in the laser brazing of a pin-to-plate joint. J Mater Process Technol 82:53–60CrossRefGoogle Scholar
  15. 15.
    Szczepaniak A, Fan J, Kostka A, Raabe D (2012) On the correlation between thermal cycle and formation of Intermetallic phases at the interface of laser-welded aluminum-steel overlap joints. Adv Eng Mater 14:464–472CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2015

Authors and Affiliations

  • Guoliang Qin
    • 1
  • Yuhu Su
    • 1
  • Xiangmeng Meng
    • 1
  • Banglong Fu
    • 1
  1. 1.Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials Ministry of EducationShandong UniversityJinanPeople’s Republic of China

Personalised recommendations