A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAW
In joining aluminum alloy to galvanized (GI) steel, the huge gap of thermophysical properties, defects by zinc from the steel surface, and formation of excessive brittle Fe-Al intermetallics (IMC) are the main factors that deteriorate the joint quality. In this study, alternating current pulse gas m...
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-03-01
|
| Series: | Metals |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-4701/11/4/561 |
| _version_ | 1797539570262212608 |
|---|---|
| author | Seong Min Hong Shinichi Tashiro Hee-Seon Bang Manabu Tanaka |
| author_facet | Seong Min Hong Shinichi Tashiro Hee-Seon Bang Manabu Tanaka |
| author_sort | Seong Min Hong |
| collection | DOAJ |
| description | In joining aluminum alloy to galvanized (GI) steel, the huge gap of thermophysical properties, defects by zinc from the steel surface, and formation of excessive brittle Fe-Al intermetallics (IMC) are the main factors that deteriorate the joint quality. In this study, alternating current pulse gas metal arc welding (AC pulse GMAW) was suggested as a solution with a mix of electrode positive and negative modes. A 1.2 mm thick AA5052 aluminum alloy and GI steel plates were joined using 1.2 mm diameter AA4047 filler wire. A comparative study on the joint interface was conducted varying the welding current and electrode-negative (EN) ratio to investigate the effect of different welding parameters on the growth of the Fe-Al intermetallics (IMC) layer, the effect of zinc, and the mechanical characteristics of the joints. It was confirmed that the change of polarity affects the distribution of zinc element in the joints. An increase in the EN ratio suppressed the growth of the IMC layer to 3.59 μm with decreased heat input. The maximum tensile-shear strength of the welded joints was approximately 171 MPa (78% joint efficiency) at the welding current of 50 A with 20% EN ratio. |
| first_indexed | 2024-03-10T12:47:42Z |
| format | Article |
| id | doaj.art-b3d1ea1740734cf993432d09a232fb94 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-10T12:47:42Z |
| publishDate | 2021-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-b3d1ea1740734cf993432d09a232fb942023-11-21T13:24:18ZengMDPI AGMetals2075-47012021-03-0111456110.3390/met11040561A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAWSeong Min Hong0Shinichi Tashiro1Hee-Seon Bang2Manabu Tanaka3Joining and Welding Research Institute, Osaka University, Osaka 567-0047, JapanJoining and Welding Research Institute, Osaka University, Osaka 567-0047, JapanDepartment of Welding and Joining Science Engineering, Chosun University, Gwangju 61452, KoreaJoining and Welding Research Institute, Osaka University, Osaka 567-0047, JapanIn joining aluminum alloy to galvanized (GI) steel, the huge gap of thermophysical properties, defects by zinc from the steel surface, and formation of excessive brittle Fe-Al intermetallics (IMC) are the main factors that deteriorate the joint quality. In this study, alternating current pulse gas metal arc welding (AC pulse GMAW) was suggested as a solution with a mix of electrode positive and negative modes. A 1.2 mm thick AA5052 aluminum alloy and GI steel plates were joined using 1.2 mm diameter AA4047 filler wire. A comparative study on the joint interface was conducted varying the welding current and electrode-negative (EN) ratio to investigate the effect of different welding parameters on the growth of the Fe-Al intermetallics (IMC) layer, the effect of zinc, and the mechanical characteristics of the joints. It was confirmed that the change of polarity affects the distribution of zinc element in the joints. An increase in the EN ratio suppressed the growth of the IMC layer to 3.59 μm with decreased heat input. The maximum tensile-shear strength of the welded joints was approximately 171 MPa (78% joint efficiency) at the welding current of 50 A with 20% EN ratio.https://www.mdpi.com/2075-4701/11/4/561AC pulse GMAWdissimilar materialsaluminum alloygalvanized steelFe-Al IMC layerweldability |
| spellingShingle | Seong Min Hong Shinichi Tashiro Hee-Seon Bang Manabu Tanaka A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAW Metals AC pulse GMAW dissimilar materials aluminum alloy galvanized steel Fe-Al IMC layer weldability |
| title | A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAW |
| title_full | A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAW |
| title_fullStr | A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAW |
| title_full_unstemmed | A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAW |
| title_short | A Study on the Effect of Current Waveform on Intermetallics Formation and the Weldability of Dissimilar Materials Welded Joints (AA5052 Alloy—GI Steel) in AC Pulse GMAW |
| title_sort | study on the effect of current waveform on intermetallics formation and the weldability of dissimilar materials welded joints aa5052 alloy gi steel in ac pulse gmaw |
| topic | AC pulse GMAW dissimilar materials aluminum alloy galvanized steel Fe-Al IMC layer weldability |
| url | https://www.mdpi.com/2075-4701/11/4/561 |
| work_keys_str_mv | AT seongminhong astudyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw AT shinichitashiro astudyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw AT heeseonbang astudyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw AT manabutanaka astudyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw AT seongminhong studyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw AT shinichitashiro studyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw AT heeseonbang studyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw AT manabutanaka studyontheeffectofcurrentwaveformonintermetallicsformationandtheweldabilityofdissimilarmaterialsweldedjointsaa5052alloygisteelinacpulsegmaw |