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Resistance spot welding of dissimilar material joints with a cold-gas-sprayed inlayer

  • In this publication, cold gas spraying (CGS) is investigated as an enabler for aluminum-steel joints. Using a powder-based coating process to adhere a steel layer to an aluminum substrate allows a steel component to be welded to the deposited layer by resistance spot welding. This method permits the metallurgical connection between similar materials to be separated, while mechanical bonding ensures the connection at the dissimilar aluminum-to-inlayer interface. A modification of the porous CGS layer, as well as the creation of the remelted zone in the aluminum, can be observed during the resistance spot welding process. Electron backscatter diffraction (EBSD) analyses show that the severely prestressed particles in the CGS coating recrystallize, which coincides with a decrease in defect density and hardness in the heat-affected zone. Microscopy of the aluminum substrate shows the creation of metallurgical pores as well as the expansion of pores attributed to the casting process. The rise in remelted aluminum hardness and decrease inIn this publication, cold gas spraying (CGS) is investigated as an enabler for aluminum-steel joints. Using a powder-based coating process to adhere a steel layer to an aluminum substrate allows a steel component to be welded to the deposited layer by resistance spot welding. This method permits the metallurgical connection between similar materials to be separated, while mechanical bonding ensures the connection at the dissimilar aluminum-to-inlayer interface. A modification of the porous CGS layer, as well as the creation of the remelted zone in the aluminum, can be observed during the resistance spot welding process. Electron backscatter diffraction (EBSD) analyses show that the severely prestressed particles in the CGS coating recrystallize, which coincides with a decrease in defect density and hardness in the heat-affected zone. Microscopy of the aluminum substrate shows the creation of metallurgical pores as well as the expansion of pores attributed to the casting process. The rise in remelted aluminum hardness and decrease in the heat-affected zone of the CGS layer indicate the formation of a metallurgical notch.show moreshow less

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Metadaten
Author: Christian Hagen, Franz-Josef Klinkenberg, Ralf OssenbrinkORCiD, Vesselin MichailovORCiDGND
URL:https://link.springer.com/article/10.1007/s00170-023-11897-x
DOI:https://doi.org/10.1007/s00170-023-11897-x
ISSN:1433-3015
ISSN:0268-3768
Title of the source (English):The International Journal of Advanced Manufacturing Technology
Document Type:Scientific journal article peer-reviewed
Language:English
Year of publication:2023
Tag:aluminium-steel weld; cgs; cold gas spray; dissimilar joint; inlayer; resistance spot weld; rsw
Number of pages:12
Fundername (not EU):Projekt DEAL
Way of publication:Open Access
Faculty/Chair:Fakultät 3 Maschinenbau, Elektro- und Energiesysteme / FG Füge- und Schweißtechnik
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