Microstructure and Strength of Ultrasonic Plus Resistance Spot Welded Aluminum Alloy to Coated Press Hardened Boron Steel


Press-hardened boron steels with ultrahigh strength (above 1500 MPa) are widely used in crash-sensitive safety components in automobiles. Joining such steels to aluminum alloys is challenging due to various factors including the steel’s tenacious Al-Si coating. A novel application of ultrasonic plus resistance spot welding was developed for such dissimilar metal joining. The nugget formation and the interface microstructure especially intermetallics formed were correlated to the joint strength, ductility and failure behavior.

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This work was funded in part by the Ohio State University Simulation Innovation and Modeling Center (SIMCenter) through support from Honda R&D Americas (HRA), Inc. The authors would like to thank Mr. Byoung Ou, Nate Pulliam, and Scott Hunter of TECH-SONIC, Inc. for supporting ultrasonic spot welding and Mr. Tim Abke of HRA for providing the materials.

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Correspondence to Wei Zhang.

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Manuscript submitted August 29, 2019.

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Lu, Y., Walker, L., Kimchi, M. et al. Microstructure and Strength of Ultrasonic Plus Resistance Spot Welded Aluminum Alloy to Coated Press Hardened Boron Steel. Metall Mater Trans A 51, 93–98 (2020). https://doi.org/10.1007/s11661-019-05524-2

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