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Dissimilar Impact Welding of 6111-T4, 5052-H32 Aluminum Alloys to 22MnB5, DP980 Steels and the Structure–Property Relationship of a Strongly Bonded Interface

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Abstract

The ability to weld high-strength aluminum to high-strength steel is highly desired for vehicle lightweighting but difficult to attain by conventional means. In this work, vaporizing foil actuator welding was used to successfully weld four Al/Fe combinations consisting of high-strength alloys: AA5052-H32, AA6111-T4, DP980, and 22MnB5. Flyer velocities up to 727 m/s were reached using 10 kJ input energy. In lap-shear testing, samples primarily failed in base aluminum near the aluminum’s native strength, showing that the welds were stronger than a base metal and that the base metal was not significantly weakened by the welding process. A particularly strong weld area was studied by transmission electron microscopy to shed light on the microstructural features of strong impact welds. It was found to be characterized by a continuously bonded, fully crystalline interface, extremely fine (nanoscale) grains, mesoscopic as well as microscopic wavy features, and lack of large continuous intermetallic compounds.

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Acknowledgments

This material is based upon work supported by the Department of Energy, Office of Energy Efficiency and Renewable Energy (EERE), under Award No. DE-EE0006451. Special thanks go to Honda Motor Company for supplying the DP980 and 22MnB5 used in this work. The TEM work was conducted in the Center for Accelerated Maturation of Materials (CAMM) at the OSU Center for Advanced Microscopy and Analysis (CEMAS).

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Authors and Affiliations

  1. Department of Materials Science and Engineering, The Ohio State University, 177 Watts Hall, 2041 N. College Rd., Columbus, OH, 43210, USA

    Bert Liu, Anupam Vivek, Michael Presley & Glenn S. Daehn

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  1. Bert Liu
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  2. Anupam Vivek
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  3. Michael Presley
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  4. Glenn S. Daehn
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Correspondence to Bert Liu.

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Manuscript submitted April 18, 2017.

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Liu, B., Vivek, A., Presley, M. et al. Dissimilar Impact Welding of 6111-T4, 5052-H32 Aluminum Alloys to 22MnB5, DP980 Steels and the Structure–Property Relationship of a Strongly Bonded Interface. Metall Mater Trans A 49, 899–907 (2018). https://doi.org/10.1007/s11661-017-4429-7

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  • DOI: https://doi.org/10.1007/s11661-017-4429-7

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