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<p>This study investigated laser beam welding of dissimilar steel and aluminum alloy in a lap configuration. The effects of defocusing distance and heat input on weld quality were examined. A defocusing distance of + 10&#xa0;mm resulted in desirable weld characteristics. Using a 3.8&#xa0;kW (38&#xa0;J/mm) heat input produced weld seams with minimal defects. XRD analysis identified Fe<sub>2</sub>Al<sub>5</sub>, FeAl, Fe<sub>3</sub>Al, and FeAl<sub>3</sub> at the Fe-Al joint interface. The formation mechanism of Fe-Al intermetallic compounds is explained in detail. The weld seam with 38&#xa0;J/mm heat input achieved the best joint performance, with a tensile load of 0.922&#xa0;kN and elongation of 0.656&#xa0;mm, surpassing those at 36&#xa0;J/mm and 40&#xa0;J/mm. The findings provide valuable insights into optimizing laser welding parameters and controlling intermetallic compounds formation, both of which are crucial for enhancing the strength and reliability of steel–aluminum joints.</p>

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Microstructure Evolution and Interfacial Reactions in Laser Beam Welded Fe–Al Joints

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年12月13日

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

摘要

This study investigated laser beam welding of dissimilar steel and aluminum alloy in a lap configuration. The effects of defocusing distance and heat input on weld quality were examined. A defocusing distance of + 10 mm resulted in desirable weld characteristics. Using a 3.8 kW (38 J/mm) heat input produced weld seams with minimal defects. XRD analysis identified Fe2Al5, FeAl, Fe3Al, and FeAl3 at the Fe-Al joint interface. The formation mechanism of Fe-Al intermetallic compounds is explained in detail. The weld seam with 38 J/mm heat input achieved the best joint performance, with a tensile load of 0.922 kN and elongation of 0.656 mm, surpassing those at 36 J/mm and 40 J/mm. The findings provide valuable insights into optimizing laser welding parameters and controlling intermetallic compounds formation, both of which are crucial for enhancing the strength and reliability of steel–aluminum joints.