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Probing joint strength and distortion in gas metal arc lap joining of aluminum and steel sheets

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Abstract

Joining of multi-metallic assemblies such as aluminum and steel sheets using fusion joining technologies is prudent although the formation of intermetallic compounds along joint interface has remained a critical challenge. An advanced, low-power input, gas metal arc process was employed here for joining of aluminum and zinc-coated steel sheets of dissimilar thicknesses in lap-joint configuration. The heat input during the process was restricted by fast responsive current and voltage pulses that allowed a synchronized arcing and short circuiting at a low arc power. The effect of heat input and thermophysical properties of base materials on the bead profile, joint strength, and distortion was studied extensively. The results indicated a rational improvement of joint quality with lowering of the heat input within a restrictive range of processing conditions such as wire feed rate and travel speed. Most importantly, the mixed-metal assembly exhibited different thermal distortions with the aluminum top sheet undergoing greater distortion than the bottom steel sheet due to a higher coefficient of thermal expansion.

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Authors and Affiliations

  1. Technical University of Applied Science, Brandenburg an der Havel, Germany

    Sven-F Goecke

  2. Indian Institute of Technology, Bombay, India

    P. Makwana & A. De

  3. Tata Steel Ltd., Jamshedpur, India

    M. Shome

Authors
  1. Sven-F Goecke
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  2. P. Makwana
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  3. M. Shome
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  4. A. De
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Corresponding author

Correspondence to Sven-F Goecke.

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Recommended for publication by Commission XII - Arc Welding Processes and Production Systems

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Goecke, SF., Makwana, P., Shome, M. et al. Probing joint strength and distortion in gas metal arc lap joining of aluminum and steel sheets. Weld World 63, 229–236 (2019). https://doi.org/10.1007/s40194-018-0653-z

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  • DOI: https://doi.org/10.1007/s40194-018-0653-z

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