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<p>This study presents an innovative synergistic strategy that combines laser beam oscillation with a microalloying Ni interlayer to join galvanized steel and aluminum alloy in a lap configuration, effectively addressing the longstanding challenge of brittle intermetallic compounds formation in Fe-Al dissimilar joints. The dynamic interplay between beam oscillation-induced agitation and the microalloying effect of Ni fundamentally reshaped the interfacial metallurgy, facilitating the development of a serrated rather than a blocky interfacial microstructure. Consequently, the interface primarily comprised Fe<sub>2</sub>Al<sub>5</sub>, FeAl<sub>3</sub>, Fe<sub>3</sub>Ni, AlNi, and Fe<sub>2</sub>Al<sub>5</sub>Zn<sub>0.4</sub> phases, leading to reduced crack susceptibility and minimized weld seam failure. Notably, this dual-action mechanism resulted in a remarkable enhancement in mechanical performance, with the tensile load increasing by 117.4% (1.08 kN) compared to conventional laser welding, representing a significant improvement in optimizing the strength-ductility balance of steel-aluminum hybrid structures.</p>

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Microstructural evolution and fracture mechanisms of steel/Al lap joints by beam oscillation welding with Ni interlayer

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年8月28日

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  • Wenchao Zhang,
  • Mohd Faridh Ahmad Zaharuddin,
  • Funwee Chen,
  • Wan Fahmin Faiz Wan Ali

摘要

This study presents an innovative synergistic strategy that combines laser beam oscillation with a microalloying Ni interlayer to join galvanized steel and aluminum alloy in a lap configuration, effectively addressing the longstanding challenge of brittle intermetallic compounds formation in Fe-Al dissimilar joints. The dynamic interplay between beam oscillation-induced agitation and the microalloying effect of Ni fundamentally reshaped the interfacial metallurgy, facilitating the development of a serrated rather than a blocky interfacial microstructure. Consequently, the interface primarily comprised Fe2Al5, FeAl3, Fe3Ni, AlNi, and Fe2Al5Zn0.4 phases, leading to reduced crack susceptibility and minimized weld seam failure. Notably, this dual-action mechanism resulted in a remarkable enhancement in mechanical performance, with the tensile load increasing by 117.4% (1.08 kN) compared to conventional laser welding, representing a significant improvement in optimizing the strength-ductility balance of steel-aluminum hybrid structures.