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<p>This study investigates the effects of Sn interlayer and perforated Sn interlayer (laser-perforated) on steel/aluminum TIG lap welding. The microstructure of weld seam was analyzed by a canning electron microscope, and the tensile-shear force of the joint was analyzed by an electronic universal testing machine. Compared to no interlayer, introducing 0.01&#xa0;mm Sn interlayer enhanced weld melt depth and width on the aluminum side and increased tensile-shear force beyond the baseline 115-125&#xa0;N/mm. However, increasing interlayer thickness to 0.03&#xa0;mm reduced strength due to impeded heat conduction, disrupting interfacial reactions. Applying the perforated Sn interlayer further improved weld dimensions slightly and maximized joint strength to 148&#xa0;N/mm. Perforating the Sn interlayer further improved weld dimensions at the interface, mitigating the negative thermal effects of thicker Sn interlayers. This stabilizes the weld pool, promotes effective metallurgical bonding, and partially suppresses continuous brittle Fe-Al intermetallic phase formation, resulting in significantly stronger joints.</p>

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Effect of Perforated Sn Interlayer on Mechanical Properties of DP780/6061 Aluminum Alloy Lap Welded Joint

  • 期刊论文

  • 发表日期：

    2026年4月23日

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  • Dan Wang,
  • Chengsen Zhu,
  • Shuai Zhang,
  • Hongliang Li,
  • Xinyi Zhao,
  • Ke Han,
  • Nan Xu,
  • Jun Shen

摘要

This study investigates the effects of Sn interlayer and perforated Sn interlayer (laser-perforated) on steel/aluminum TIG lap welding. The microstructure of weld seam was analyzed by a canning electron microscope, and the tensile-shear force of the joint was analyzed by an electronic universal testing machine. Compared to no interlayer, introducing 0.01 mm Sn interlayer enhanced weld melt depth and width on the aluminum side and increased tensile-shear force beyond the baseline 115-125 N/mm. However, increasing interlayer thickness to 0.03 mm reduced strength due to impeded heat conduction, disrupting interfacial reactions. Applying the perforated Sn interlayer further improved weld dimensions slightly and maximized joint strength to 148 N/mm. Perforating the Sn interlayer further improved weld dimensions at the interface, mitigating the negative thermal effects of thicker Sn interlayers. This stabilizes the weld pool, promotes effective metallurgical bonding, and partially suppresses continuous brittle Fe-Al intermetallic phase formation, resulting in significantly stronger joints.