Determination of Weld Interface Properties and their Effect on the Strength of Multi-Material Aluminium-Steel Joints
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Date
2025-08-26
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Abstract
Collision welding is a promising manufacturing approach for joining similar and dissimilar
metals without thermally influenced strength loss. This capability unlocks new potential for
lightweight construction. Among other things, components and welded joints can be made
more filigree and load-optimised. Widespread industrial use of this technology is still limited
by insufficient knowledge of the underlying joining mechanisms. In this paper, collision
welding is applied to an aluminium-steel material combination of steel (DC04) and
aluminium (AA6016). First, the welding process window for the material combination is
determined on a special model test rig by varying the collision speed and the collision angle,
the two main process parameters in collision welding. Shear tensile tests are then conducted
to refine the weld process window, focusing on the region exhibiting the highest shear tensile
strength values. Scanning Electron Microscope (SEM) images are used to analyse the weld
zone, revealing the formation of four different metallographic structures in the joint zone of
the welded samples. The area fractions of these structures are quantified and correlated with
collision angles and corresponding shear tensile strength values.
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Keywords
Collision welding, Emission Reduction, Lightweight Concepts, Multi-Material Design
Subjects based on RSWK
Elektromagnetisches Pulsschweißen, Werkstoffpaarung, Aluminium, Stahl, Leichtbau, Emissionsverringerung, Schweißnaht, Schweißnahtprüfung, Rasterelektronenmikroskop