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Novel projection welding technology for joining of steel-aluminum hybrid components—part 1: technology and its potential for industrial use

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Abstract

Multi-material design offers cost-efficient lightweight solutions for automotive body-in-white production. Ultra-high strength steels remain an essential part of the lightweight construction and are increasingly used in combination with components made of aluminum alloys in multi-material body designs. For these applications, the commonly used joining processes (riveting, clinching, resistance spot welding, etc.) have been pushed to their technological limits and a further technological development is needed. The present research describes a new joining technology based on resistance welding process for joining ultra-high strength steel 22MnB5 (AS150) with aluminum sheets AW 6016. The technology consists of a two-stage resistance spot welding process with an additional simple cost-effective joining element. Its implementation allows joining aluminum and steel on extremely short flanges of 10 mm using short time projection welding with high-energy concentration. Joining elements—cylinders made of Cu- and Fe-based wires with diameter 1.6 mm and length 10 mm - were welded using the common resistance spot welding equipment. Experimental results have shown that all tested materials for joining dissimilar steel-aluminum compounds can be successfully used and the weld current ranges are sufficient for industrial application.

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Acknowledgments

The authors would like to thank AiF for funding the IGF-Project IGF-No. 20164 BR/FOSTA P1294 of the German Research Association for Steel Application (FOSTA), which was part of the program to support cooperative industrial research (Industrielle Gemeinschaftsförderung (IGF)) by the Federal Ministry for Economic Affairs and Energy, following a decision of the German Bundestag. Equal thanks go to all companies, colleagues, and students who contributed their support, knowledge, and effort to the project.

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  1. Institute of Materials and Joining Technology (IWF), Otto von Guericke University Magdeburg, Universitätsplatz 2, 39106, Magdeburg, Germany

    Anastasiia Zvorykina, Oleksii Sherepenko & Sven Jüttner

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  1. Anastasiia Zvorykina
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  2. Oleksii Sherepenko
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  3. Sven Jüttner
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Correspondence to Anastasiia Zvorykina.

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Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

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Zvorykina, A., Sherepenko, O. & Jüttner, S. Novel projection welding technology for joining of steel-aluminum hybrid components—part 1: technology and its potential for industrial use. Weld World 64, 317–326 (2020). https://doi.org/10.1007/s40194-019-00833-x

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