Characterization of Joints Between Aluminum and Galvanized Steel Sheets

Sound joints between an AA6016 aluminum sheet of 1.2-mm thickness and a low-carbon galvanized steel sheet of 0.77-mm thickness are obtained using the laser pseudo-brazing method. A zinc-based aluminum alloy is used as a filler wire with optimized process parameters for laser pseudo-brazing. Metallurgical investigation of the joint is carried out using a scanning electron microscope and energy-dispersive X-ray analysis. Joints produced using Al-Zn filler wire showed a moderate strength and quality with a layer containing principally Fe₂Al₅Zn _x type intermetallics of ~10-μm thickness. Failure in the heat-affected zone of aluminum is found to be dominative, while in some cases, fracture along the interface between the intermetallic layer and the steel sheet is observed.     

Thermochemical Analysis of Phases Formed at the Interface of a Mg alloy-Ni-plated Steel Joint during Laser Brazing

The thermodynamic stability of precipitated phases at the steel-Ni-Mg alloy interface during laser brazing of Ni-plated steel to AZ31B magnesium sheet using AZ92 magnesium alloy filler wire has been evaluated using FactSage thermochemical software. Assuming local chemical equilibrium at the interface, the chemical activity–temperature–composition relationships of intermetallic compounds that might form in the steel-Ni interlayer-AZ92 magnesium alloy system in the temperature range of 873 K to 1373 K (600 °C to 1100 °C) were estimated using the Equilib module of FactSage. The results provided better understanding of the phases that might form at the interface of the dissimilar metal joints during the laser brazing process. The addition of a Ni interlayer between the steel and the Mg brazing alloy was predicted to result in the formation of the AlNi, Mg₂Ni, and Al₃Ni₂ intermetallic compounds at the interface, depending on the local maximum temperature. This was confirmed experimentally by laser brazing of Ni electro-plated steel to AZ31B-H24 magnesium alloy using AZ92 magnesium alloy filler wire. As predicted, the formation of just AlNi and Mg₂Ni from a monotectic and eutectic reaction, respectively, was observed near the interface.     

Thixo‐Forging and Thixo‐Joining of an Integrated Product

In an effort to investigate thixo‐joining of aluminium alloy AISi7Mg with bolts of different metals, a series of experiments was carried out. An aluminium master part of high geometric complexity was thixo‐forged. Then thixo‐joining experiments were conducted. While the thixo‐forging of the aluminium master part being completed, bolts of brass, copper, plain carbon steel and stainless steel were integrated into the thixo‐forged part in one step. Evaluations of the produced parts were performed with X‐ray inspection, microstructure and segregation analyses. The experimental results confirm that the aluminium alloy A356 has good formability in semi‐solid state and that the thixo‐joining of the metal bolts with the aluminium part in one step is feasible.     

Development of an Aluminized Multi‐Phase Steel with Dual Phase Properties for High Temperature Corrosion Resistance Applications

A high strength, high Mn, Cr‐Mo containing multi‐phase steel grade was aluminized with a 90 wt% Al – 10 wt% Si alloy coating, using a laboratory hot‐dip simulator. The adhesion of the coating to the steel strip was evaluated and the microstructure of the as deposited material was assessed. The coated sheet steel was tested at high temperatures by monitoring the weight gain of the samples and their mechanical properties as a function of time. It was found that the thermal properties of the aluminized sheet were excellent. The analysis of the coating/substrate interface revealed the dissolution of brittle intermetallic phases, explaining the excellent high temperature resistance performance of the Al‐Si coating up to temperatures as high as 900°C. In addition, the use of a continuous annealing cycle common in current aluminizing lines, resulted in a dual phase microstructure.     

Effect of Cr2O3 Addition on Sintering Behavior of Novel Chromite-Based Ladle Filler Sand

Developing novel filler sands has garnered significant interest in improving the ladle's free-opening rate and enhancing the cleanliness of high-Mn and high-Al steel. Laboratory studies explore the effect of adding Cr₂O₃ powder on the sintering behavior of chromite-based filler sands. Furthermore, interfacial phenomena are examined between the sands and the steel grades, varying in Mn contents. The results demonstrate that adding Cr₂O₃ power plays a role in inhibiting the liquid phase formation in the sand. With a 16% addition, the steel (Mn mass% = 30) reacts with the sand, leading to the shape of a spinel phase, specifically (Mn, Fe, Mg)O·(Al, Cr)₂O₃, which facilitates the separation of the liquid phase. The reduction of FeO to Fe by Mn, Al, and C in steel, especially Al, is hindered by adding Cr₂O₃, resulting in a suitable sintering degree that ultimately benefits ladle free-opening. SiO₂ is crucial for forming the liquid phase during the sintering process. The SiO₂ content of the sand should be about 20% to achieve optimal sintering effects. Chromite sand for casting is not suitable for the steels. The mixed sand presented in the current study demonstrates potential as a suitable filler sand for the steel (20 ≤ Mn mass% ≤ 30).     

Surface and Coating Analysis of Press‐Hardened Hot‐Dip Galvanized Steel Sheet

The use of continuous galvanized steel sheet as feedstock material for press hardening leads to components of very high strength levels with classical cathodic corrosion protection. The present work provides an insight into this technology with special focus on surface oxidation and intermetallic phase formation during the austenisation process. For that reason hot dipped galvanized 22MnB5 steel sheets, with a blank thickness of 1.5 mm and an average coating weight of 70 g m^?2, were annealed in a temperature range of 400–900°C in steps of 50°C without soaking before quenching in water. Surface and cross‐cuts were analyzed by SEM, EDX, and XRD to illustrate the phase formation and the surface changes during thermal treatment. Corrosion behavior was also studied based on electrochemical investigations and an accelerated, cyclic, automotive corrosion tests called VDA, which is a mixture of salt spray test and alternating climate test. It was found that austenisation of galvanized steel sheet causes a significant change of the coating. The generated coating still offers cathodic protection for the steel substrate and has higher corrosion resistance than standard galvanized steel sheet. Surface oxidation also occurs during the press hardening process leading to a surface covered with successively arranged layers of Al₂O₃ and ZnO, containing also further oxidized alloying elements.     

Effect of Manganese on the Formation of Fe-rich Phases in Electromagnetic Stirred Hypereutectic Al-22Si Alloy with 2 % Fe

The effect of Mn on the microstructure of electromagnetic stirred hypereutectic Al-22Si-2Fe (% w/w) alloys was studied. The results show that the alloy with a Mn/Fe ratio zero, contained plentiful α-Al₄FeSi₂ phases existing as mainly intermetallic compounds in the solidified microstructures by electromagnetic stirring (EMS) process. With EMS process, the alloy with 0.61 % Mn contained acicular β-Al₅(Fe, Mn)Si, δ-Al₄(Fe, Mn)Si₂ and blocky α-Al₁₅(Fe, Mn)₃Si₂ phases in the solidification microstructure of the stirred A1 alloy. As the Mn/Fe ratio increased to 1, intermetallic compounds were mainly in the form of blocky and fine α-Al₁₅(Fe, Mn)₃Si₂ phases in the microstructure. The intermetallic compounds were examined with an optical microscope, scanning electron microscope, and X-ray diffraction. The acicular δ-Al₄(Fe, Mn)Si₂ and blocky α-Al₁₅(Fe, Mn)₃Si₂ phases were also analyzed by transmission electron microscopy.     

Microstructure and Interfacial Reactions During Active Metal Brazing of Stainless Steel to Titanium

Microstructural evolution and interfacial reactions during active metal vacuum brazing of Ti (grade-2) and stainless steel (SS 304L) using a Ag-based alloy containing Cu, Ti, and Al was investigated. A Ni-depleted solid solution layer and a discontinuous layer of (Ni,Fe)₂TiAl intermetallic compound formed on the SS surface and adjacent to the SS-braze alloy interface, respectively. Three parallel contiguous layers of intermetallic compounds, CuTi, AgTi, and (Ag,Cu)Ti₂, formed at the Ti-braze alloy interface. The diffusion path for the reaction at this interface was established. Transmission electron microscopy revealed formation of nanocrystals of Ag-Cu alloy of size ranging between 20 and 30 nm in the unreacted braze alloy layer. The interdiffusion zone of β-Ti(Ag,Cu) solid solution, formed on the Ti side of the joint, showed eutectoid decomposition to lamellar colonies of α-Ti and internally twinned (Cu,Ag)Ti₂ intermetallic phase, with an orientation relationship between the two. Bend tests indicated that the failure in the joints occurred by formation and propagation of the crack mostly along the Ti-braze alloy interface, through the (Ag,Cu)Ti₂ phase layer.     

Galvannealing of (High‐)Manganese‐Alloyed TRIP‐ and X‐IP®‐Steel

In this study the influence of Mn on galvannealed coatings of 1.7% Mn‐1.5% Al TRIP‐ and 23% Mn X‐IP®‐steels was investigated. It is shown that the external selective oxides like Mn, Al and Si of the TRIP steel which occur after annealing at 800 °C for 60 s at a dew point (DP) of ‐25 °C (5% H₂) hamper the Fe/Zn‐reaction during subsequent galvannealing. Preoxidation was beneficially utilized to increase the surface‐reactivity of the TRIP steel under the same dew point conditions. The influence of Mn on the steel alloy was investigated by using a 23% Mn containing X‐IP®‐steel which was bright annealed at 1100 °C for 60 s at DP ‐50 °C (5% H₂) to obtain a mainly oxide free surface prior to hot dip galvanizing (hdg) and subsequent galvannealing. As well known from the literature Mn alloyed to the liquid zinc melt stabilizes δ‐phase at lower temperatures by participating in the Fe‐Zn‐phase reactions, it was expected that the metallic Mn of the X‐IP®‐steel increases the Fe/Zn‐reactivity in the same manner. The approximation of the effective diffusion coefficient (D_eff(Fe)) during galvannealing was found to be higher than compared to a low alloyed steel reference. Contrary to the expectation no increased Fe/Zn‐reaction was found by microscopic investigations. Residual η‐ and ζ‐phase fractions prove a hampered Fe/Zn‐reaction. As explanation for the observed hampered Fe/Zn‐reaction the lower Fe‐content of the high‐Mn‐alloyed X‐IP®‐steel was suggested as the dominating factor for galvannealing.     

Dissimilar Friction-Stir Lap Joining of 5083 Aluminum Alloy to CuZn34 Brass

In this research, lap joining of Al-Mg aluminum alloy and CuZn34 brass was produced by friction-stir welding during which the aluminum alloy sheet was placed on the CuZn34. Optical microscopy, scanning electron microscopy (SEM), X-ray diffraction analysis, and energy-dispersive X-ray spectroscopy (EDS) analysis were used to probe the microstructures and chemical compositions. In addition, the mechanical properties of each sample are characterized using both shear and hardness tests. The optimum parameters resulted in no visible welding cracks and defects. A dark area in the Al/CuZn34 interface contained intermetallic compounds Al₂Cu, Al₄Cu₉, and CuZn. In addition, the results show that using high rotational speeds or low traverse speeds causes the growth of the interfacial intermetallic area.     

Experimental and Numerical Study of Electromagnetic Forming of AZ31B Magnesium Alloy Sheet

Wrought magnesium alloys are interesting materials for automotive and aeronautical industries due to their low density in comparison to steel and aluminium alloys, making them ideal candidates when designing a lower weight vehicle. However, due to their hexagonal close‐packed (hcp) crystal structure, magnesium alloys exhibit low formability at room temperature. For that reason, in this study a high velocity forming process, electromagnetic forming (EMF), was used to study the formability of AZ31B magnesium alloy sheet at high strain rates. In the first stage of this work, specimens of AZ31B magnesium alloy sheet have been characterised by uniaxial tensile tests at quasi‐static and dynamic strain rates at room temperature. The influence of the strain rate is outlined and the parameters of Johnson‐Cook constitutive material model were fit to experimental results. In the second stage, sheets of AZ31B magnesium alloy have been biaxially deformed by electromagnetic forming process using different coil and die configurations. Deformation values measured from electromagnetically formed parts are compared to the ones achieved by conventional forming technologies. Finally, numerical study using an alternative method for computing the electromagnetic fields in the EMF process simulation, a combination of Finite Element Method (FEM) for conductor parts and Boundary Element Method (BEM) for insulators, is shown.     

M8011H16铝合金防盗盖板生产工艺研究

研究了元素含量变化对8011铝合金防盗盖板综合性能的影响，在8011合金中改变Cu、Mn元素含量后可提高防盗盖板的强度，同时研究了烘烤处理后的强度变化问题。本文研究出了8011铝合金防盗盖板新的生产工艺制度。     

Investigation on effect of pulse correction on structure property in dissimilar welds of galvanized steel and aluminum alloy obtained by gas metal arc welding cold metal transfer

Gas metal arc welding cold metal transfer (GMAW-CMT) method with AlSi₃Mn filler wire was performed on welding of the 5754 aluminum alloy with thickness of 3 mm to the galvanized steel with thickness of 2 mm aluminum alloy to investigate the effect of pulse correction on structure and mechanical properties of welded samples. In accordance with results, GMAW-CMT provides good tensile performance. It was attributed to the various throat weld size and wetting actions because of the influence of pulse correction on structure of welded joints. It was inferred that on employing +5 pulse correction resulted in better and consistent tensile strength of 209 MPa. Furthermore, the results showed that increasing the pulse correction led to increasing of flow in the filler wire and in fact raising of brazed seam width and throat weld size. In addition, the thickness of intermetallic compound layer which was formed along the interface during the GMAW-CMT was varied by changing of pulse correction. It has been found that by increasing the pulse correction from–5 to +5, the throat weld size increased and consequently led to a change in the tensile strength of the welded joints.     

The microstructure of an Fe-Mn-Si-Cr-Ni stainless steel shape memory alloy

The microstructure and phase stability of the Fe-15Mn-7Si-9Cr-5Ni stainless steel shape memory alloy in the temperature range of 600 °C to 1200 °C was investigated using optical and transmission electron microscopy, X-ray diffractometry (XRD), differential scanning calorimetry (DSC), and chemical analysis techniques. The microstructural studies show that an austenite single-phase field exists in the temperature range of 1000 °C to 1100 °C, above 1100 °C, there exists a three-phase field consisting of austenite, δ-ferrite, and the (Fe,Mn)₃Si intermetallic phase; within the temperature range of 700 °C to 1000 °C, a two-phase field consisting of austenite and the Fe₅Ni₃Si₂ type intermetallic phase exists; and below 700 °C, there exists a single austenite phase field. Apart from these equilibrium phases, the austenite grains show the presence of athermal ɛ martensite. The athermal α′ martensite has also been observed for the first time in these stainless steel shape memory alloys and is produced through the γ-ɛ-α′ transformation sequence.     

Effect of Surface Tension on Gas Atomization of a CrMnNi Steel Alloy

The aim of the current research is the experimental investigation of the mass median particle size d₅₀ as a function of surface tension for liquid Cr–Mn–Ni steel alloy with 16% Cr, 7% Mn, and 9% Ni. To modify the liquid steel design sulfur was add to the Cr–Mn–Ni steel in five steps up to a 1000 mass ppm. The surface tension of the liquid steel alloy was measured using maximum bubble pressure method and yttria stabilized capillary in a temperature range from 1701 to 1881 K. In addition, the same steel charges were sprayed to steel powder using a vacuum inert gas atomization using pure argon gas. The increase of sulfur in Cr–Mn–Ni steel will decrease the surface tension to 0.91 N m^?1. The temperature coefficient of surface tension is positive for all investigated Cr–Mn–Ni alloys due to a sulfur content ≥100 mass ppm. The final mass median particle size d₅₀ decreases from 54.3 µm for AISI 304 reference steel alloy to 17.1 µm for Cr–Mn–Ni steel alloy (16‐7‐9 S10) with the highest sulfur content and the lowest surface tension of all investigated liquid steels. It is concluded from the present work that surface tension is the decisive factor in adjusting d₅₀ at a constant spraying parameters.     

Heterogeneous Nucleation of α-Al Grain on Primary α-AlFeMnSi Intermetallic Investigated Using 3D SEM Ultramicrotomy and HRTEM

Microstructural examination of the Al-5.3Mg-2.4Si-0.6Mn-1.0Fe alloy in the die-cast condition revealed that a significant number of the primary α-AlFeMnSi intermetallic particles were found inside both the coarse α-Al dendrite fragments formed in the shot sleeve and the fine α-Al grains formed in the die cavity. The heterogeneous nucleation of α-Al phase on primary α-AlFeMnSi intermetallic particle was further investigated experimentally. 3-Dimension (3D) scanning electron microscopy ultramicrotomy revealed that the probability of finding at least one primary α-AlFeMnSi intermetallic particle inside each α-Al grain was almost 90 pct. The detailed microstructural analysis identified the primary α-AlFeMnSi intermetallic particle as the α-Al₁₂(Fe,Mn)₃Si composition with a body-centered cubic structure and a lattice parameter of a = 1.265 nm. It was found that the primary α-Al₁₂(Fe,Mn)₃Si intermetallic particle had a faceted morphology with {110} planes exposed as its natural surfaces. High resolution transmission electron microscopy further confirmed that the crystallographic orientation relationship between α-Al₁₂(Fe,Mn)₃Si intermetallic particle and α-Al phase was: [111]_α-AlFeMnSi//[110]_Al and (1 \( \overline{1} \) 0)_α-AlFeMnSi~6 deg from (1 \( \overline{1} \) 1)_α-Al, and the corresponding interface between two phases could be confirmed as a semi-coherent interface with a lattice misfit of 2.67 pct at 933 K (660 °C), which was considerably smaller than the theoretical limit (5.7 pct) for epitaxial nucleation. Finally, based on these experimental evidences and the epitaxial nucleation model, we concluded that the primary α-Al₁₂(Fe,Mn)₃Si intermetallic particles were both potent and effective nucleating substrates for the α-Al phase.     

Phase and Microstructural Analysis of Hot Rolled FeNi42 Sheet,its Response in Magnetic and Mechanical Properties

Inclusions unavoidably existing in steels and consequently also in final products obtained by e.g. rolling markedly affects the physical properties. This paper is devoted to investigation of FeNi42 steel hot rolled into a sheet form. The structural and phase analysis is done by scanning electron microscopy, X‐ray diffraction, and Mössbauer spectroscopy completed by magnetic and hardness measurements. The results yield an inhomogeneous nickel distribution in the sheet resulting in a formation of the intermetallic Ni₃Fe phase. A depletion of sheet surface by nickel leads to an intensive surface oxidation; its thickness increases in the direction of sheet edges. The non‐metallic oxide inclusions are concentrated predominantly at grain boundaries, which contribute to an easier cracking. The formation of Ni₃Fe affects a small increase in saturation magnetization. The oxides and consequently cracks formation cause magnetic hardening as can be seen on an increase of the structurally sensitive remnant magnetization. The hard oxide inclusions evoke also the hardening of material, rise brittleness and crack liability.     

Improvement of the Galvanized Coating Quality of High Strength Dual Phase Steels by Pre‐Electroplating Nickel Layer

Galvanized dual phase steel sheets are used extensively in the industrial applications because of their excellent mechanical properties and superior corrosion resistance, but the segregation of alloying elements and the formation of oxides on the steel surface often have a deleterious effect on coating adhesion during the galvanizing process. In order to improve the coating quality, a nickel layer was pre‐electroplated on the steel substrate before galvanizing and it's found that there is an improvement in the coating quality. The coating microstructures were investigated by scanning electron microscopy together with energy dispersive X‐ray spectroscope, glow discharge optical emission spectroscope and X‐ray diffractions. The experimental results show that the compact Ni₃Zn₂₂ intermetallic layer formed at the zinc/nickel interface during the galvanizing process, prohibiting the nucleation and the growth of the ζ‐Zn phase layer and resulting in the improvement of the zinc coating adhesion.     

The Effect of In Situ Intermetallic Formation on Al-Sn Foaming Behavior

The effect of in situ intermetallic formation on the foaming behavior of Al-3 wt pct Sn alloy has been investigated by introducing five different alloying elements—Co, Mg, Mn, Ni, and Ti. The alloying elements were designed, using thermodynamic calculations, to form various intermetallic phases which are (i) stable until final foaming temperature and (ii) dissolved during the foaming process. Thermal analysis using DSC was carried out to characterize the formation and dissolution of intermetallic phases during the foaming process. The foaming tests of the Al-3 wt pct Sn-X alloy were carried out using a mechanical expandometer and the macrostructure of the foam was scanned with an X-ray tomographer. It is found that the foaming behavior and foam stability of Al-3 wt pct Sn alloy can be actively controlled by the alloying elements.