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Meeting the challenge of thermal joining of steel and aluminum using a new approach based on melt displacement by electromagnetic forces

  • Environmental protection, resource conservation and CO2 reduction require new joining concepts for effective multi-material design in automotive lightweight construction. The thermal joining of dissimilar materials, especially the combination of aluminum alloys and steel, is associated with difficulties. Different material properties, such as melting point and coefficient of thermal expansion, complicate joining processes. Furthermore, the insolubility between these materials results in the formation of intermetallic phases. These brittle phases reduce the load-bearing capacity and quality of the joints. The thickness of the intermetallic phases should not reach the critical value of 10 μm to ensure good mechanical properties of the joint. It is known that a two-phase reaction layer consisting of Al5Fe2 and Al3Fe (also known as Al13Fe4) forms at the interface between solid steel and liquid aluminum. Due to high cooling rates, as it is the case in laser beam welding, metastableEnvironmental protection, resource conservation and CO2 reduction require new joining concepts for effective multi-material design in automotive lightweight construction. The thermal joining of dissimilar materials, especially the combination of aluminum alloys and steel, is associated with difficulties. Different material properties, such as melting point and coefficient of thermal expansion, complicate joining processes. Furthermore, the insolubility between these materials results in the formation of intermetallic phases. These brittle phases reduce the load-bearing capacity and quality of the joints. The thickness of the intermetallic phases should not reach the critical value of 10 μm to ensure good mechanical properties of the joint. It is known that a two-phase reaction layer consisting of Al5Fe2 and Al3Fe (also known as Al13Fe4) forms at the interface between solid steel and liquid aluminum. Due to high cooling rates, as it is the case in laser beam welding, metastable intermetallic compounds can form different from the equilibrium state. The formation of the intermetallic reaction layer is a diffusion-controlled process. So, it is only possible to control the growth of these phases. This problem has led to use joining methods that do not require the melting of both joining partners. A promising joining method is laser beam welding-brazing, whereby only one joining partner is melted and wets the solid joining partner. Conventional laser beam welding-brazing only results in material-fit joints and often requires the use of expensive filler materials. An additional form-fit could optimize the mechanical performance of the joint. For this reason, a new joining method for overlap configurations of dissimilar materials was developed. A laser beam melts the lower joining partner through a cavity of the upper joining partner. The created melt pool is moved upwards into the cavity of the upper joining partner due to contactless induced Lorentz forces of an AC-magnetic system. The displaced melt creates a form- and material-fit joint after solidification. The advantage of this joining technology is the absence of filler materials, flux agents and expensive auxiliary joining elements.zeige mehrzeige weniger

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  • Hessmann_Hilgenberg_Extended_Abstract_Hybrid_2022.pdf
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    Article

  • Book_of_Abstracts_2022_Hybrid_2022_Imprint.pdf
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    Imprint

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Metadaten
Autor*innen:Jennifer HeßmannORCiD, Kai HilgenbergORCiD
Persönliche Herausgeber*innen:J. M. Hausmann
Dokumenttyp:Beitrag zu einem Tagungsband
Veröffentlichungsform:Graue Literatur
Sprache:Englisch
Titel des übergeordneten Werkes (Englisch):5th international conference on hybrid materials and structures 2022 - Book of abstracts
Jahr der Erstveröffentlichung:2022
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.6 Additive Fertigung metallischer Komponenten
Verlag:Deutsche Gesellschaft für Materialkunde (DGM)
Verlagsort:Sankt Augustin
Erste Seite:6
Letzte Seite:8
Freie Schlagwörter:Electromagnetic forces; Joining dissimilar materials; Laser beam welding; Steel and aluminium
Themenfelder/Aktivitätsfelder der BAM:Material
Veranstaltung:5th International Conference Hybrid 2022 - Materials and Structures
Veranstaltungsort:Leoben, Austria
Beginndatum der Veranstaltung:20.07.2022
Enddatum der Veranstaltung:22.07.2022
ISBN:978-3-88355-426-6
Zugehöriger Identifikator:https://opus4.kobv.de/opus4-bam/frontdoor/index/index/docId/55534
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:02.09.2022
Referierte Publikation:Nein
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