Scholarlink

<p>Welding aluminum and steel creates an intermetallic compound (IMC) layer at their interface. The thickness of this layer significantly affects the strength of the joint. Therefore, numerical simulation of the welding process is a popular method for controlling IMC thickness. However, the current literature lacks evidence supporting the reliability of such models, particularly for TIG welding. In this study, we developed a finite element model of the Fe-Al TIG welding process linked to a pure diffusion model to predict the thickness of the IMC from various welding conditions. Following a multi-condition calibration procedure, we demonstrate that the model can predict IMC thickness over a wide range of conditions: arc currents from 132&#xa0;A to 150&#xa0;A and welding speeds from 140&#xa0;mm/min to 230&#xa0;mm/min. Quantitative predictions of the impact of changing the backing plate material from steel to copper demonstrate the model’s robustness while highlighting the dominant impact of interface conductance compared to bulk properties. Investigations regarding heat fluxes suggest that the Fe-Al contact state outside the arc’s wake is negligible. We note that diffusion parameters <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(k_0\)</EquationSource> </InlineEquation> and <i>Q</i> tend to compensate each other and cannot be calibrated simultaneously. Finally, the estimated formation kinetics of the IMC suggest that a rapid growth stage is triggered by critical values of the interface heating rate.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Simulation of the intermetallic compound layer formation in aluminum-steel arc welding

  • 期刊论文

  • 发表日期：

    2026年1月24日

查看全文
  • Benjamin Leflon,
  • Thibaut Chaise,
  • Christophe Le Bourlot,
  • Nicolas Mary,
  • Shun Tokita,
  • Yutaka S. Sato,
  • Sylvain Dancette

摘要

Welding aluminum and steel creates an intermetallic compound (IMC) layer at their interface. The thickness of this layer significantly affects the strength of the joint. Therefore, numerical simulation of the welding process is a popular method for controlling IMC thickness. However, the current literature lacks evidence supporting the reliability of such models, particularly for TIG welding. In this study, we developed a finite element model of the Fe-Al TIG welding process linked to a pure diffusion model to predict the thickness of the IMC from various welding conditions. Following a multi-condition calibration procedure, we demonstrate that the model can predict IMC thickness over a wide range of conditions: arc currents from 132 A to 150 A and welding speeds from 140 mm/min to 230 mm/min. Quantitative predictions of the impact of changing the backing plate material from steel to copper demonstrate the model’s robustness while highlighting the dominant impact of interface conductance compared to bulk properties. Investigations regarding heat fluxes suggest that the Fe-Al contact state outside the arc’s wake is negligible. We note that diffusion parameters \(k_0\) and Q tend to compensate each other and cannot be calibrated simultaneously. Finally, the estimated formation kinetics of the IMC suggest that a rapid growth stage is triggered by critical values of the interface heating rate.