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Title: Characterization of intermetallics in aluminum to zinc coated interstitial free steel joining by pulsed MIG brazing for automotive application

Abstract

In order to meet the demand for lighter and more fuel efficient vehicles, a significant attempt is currently being focused toward the substitution of aluminum for steel in the car body structure. It generates vital challenge with respect to the methods of joining to be used for fabrication. However, the conventional fusion joining has its own difficulty owing to formation of the brittle intermetallic phases. In this present study AA6061-T6 of 2 mm and HIF-GA steel sheet of 1 mm thick are metal inert gas (MIG) brazed with 0.8 mm Al–5Si filler wire under three different heat inputs. The effect of the heat inputs on bead geometry, microstructure and joint properties of MIG brazed Al-steel joints were exclusively studied and characterized by X-ray diffraction, field emission scanning electron microscopy (FESEM), electron probe micro analyzer (EPMA) and high resolution transmission electron microscopy (HRTEM) assisted X-ray spectroscopy (EDS) and selective area diffraction pattern. Finally microstructures were correlated with the performance of the joint. Diffusion induced intermetallic thickness measured by FESEM image and concentration profile agreed well with the numerically calculated one. HRTEM assisted EDS study was used to identify the large size FeAl{sub 3} and small size Fe{sub 2}Al{sub 5} type intermetallicmore » compounds at the interface. The growth of these two phases in A2 (heat input: 182 J mm{sup −1}) is attributed to the slower cooling rate with higher diffusion time (~ 61 s) along the interface in comparison to the same for A1 (heat input: 155 J mm{sup −1}) with faster cooling rate and shorter diffusion time (~ 24 s). The joint efficiency as high as 65% of steel base metal is achieved for A2 which is the optimized parameter in the present study. - Highlights: • AA 6061 and HIF-GA could be successfully joined by MIG brazing. • Intermetallics are exclusively studied and characterized by XRD, FESEM and EPMA. • Intermetallic formation by diffusion is worth considering or not. • HRTEM-EDS, SAD pattern identifies the morphologies and size of intermetallics. • A compromise concerning formation of IMC is necessary.« less

Authors:
 [1];  [1];  [1];  [2]
  1. Metallurgical and Material Engineering Department, Jadavpur University, Kolkata–700032 (India)
  2. Material Characterization & Joining Group, R & D, Tata Steel, Jamshedpur–831007 (India)
Publication Date:
OSTI Identifier:
22587105
Resource Type:
Journal Article
Resource Relation:
Journal Name: Materials Characterization; Journal Volume: 112; Other Information: Copyright (c) 2016 Elsevier Science B.V., Amsterdam, The Netherlands, All rights reserved.; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 77 NANOSCIENCE AND NANOTECHNOLOGY; ABSORPTION SPECTROSCOPY; ABUNDANCE; BRAZING; DIFFUSION; ELECTRON MICROPROBE ANALYSIS; ELECTRON SCANNING; INTERMETALLIC COMPOUNDS; MICROSTRUCTURE; SCANNING ELECTRON MICROSCOPY; STEELS; TRANSMISSION ELECTRON MICROSCOPY; X RADIATION; X-RAY DIFFRACTION; X-RAY SPECTROSCOPY; ZINC

Citation Formats

Basak, Sushovan, E-mail: sushovanbasak@gmail.com, Das, Hrishikesh, E-mail: hrishichem@gmail.com, Pal, Tapan Kumar, E-mail: tkpal.ju@gmail.com, and Shome, Mahadev, E-mail: mshome@tatasteel.com. Characterization of intermetallics in aluminum to zinc coated interstitial free steel joining by pulsed MIG brazing for automotive application. United States: N. p., 2016. Web. doi:10.1016/J.MATCHAR.2015.12.030.
Basak, Sushovan, E-mail: sushovanbasak@gmail.com, Das, Hrishikesh, E-mail: hrishichem@gmail.com, Pal, Tapan Kumar, E-mail: tkpal.ju@gmail.com, & Shome, Mahadev, E-mail: mshome@tatasteel.com. Characterization of intermetallics in aluminum to zinc coated interstitial free steel joining by pulsed MIG brazing for automotive application. United States. doi:10.1016/J.MATCHAR.2015.12.030.
Basak, Sushovan, E-mail: sushovanbasak@gmail.com, Das, Hrishikesh, E-mail: hrishichem@gmail.com, Pal, Tapan Kumar, E-mail: tkpal.ju@gmail.com, and Shome, Mahadev, E-mail: mshome@tatasteel.com. Mon . "Characterization of intermetallics in aluminum to zinc coated interstitial free steel joining by pulsed MIG brazing for automotive application". United States. doi:10.1016/J.MATCHAR.2015.12.030.
@article{osti_22587105,
title = {Characterization of intermetallics in aluminum to zinc coated interstitial free steel joining by pulsed MIG brazing for automotive application},
author = {Basak, Sushovan, E-mail: sushovanbasak@gmail.com and Das, Hrishikesh, E-mail: hrishichem@gmail.com and Pal, Tapan Kumar, E-mail: tkpal.ju@gmail.com and Shome, Mahadev, E-mail: mshome@tatasteel.com},
abstractNote = {In order to meet the demand for lighter and more fuel efficient vehicles, a significant attempt is currently being focused toward the substitution of aluminum for steel in the car body structure. It generates vital challenge with respect to the methods of joining to be used for fabrication. However, the conventional fusion joining has its own difficulty owing to formation of the brittle intermetallic phases. In this present study AA6061-T6 of 2 mm and HIF-GA steel sheet of 1 mm thick are metal inert gas (MIG) brazed with 0.8 mm Al–5Si filler wire under three different heat inputs. The effect of the heat inputs on bead geometry, microstructure and joint properties of MIG brazed Al-steel joints were exclusively studied and characterized by X-ray diffraction, field emission scanning electron microscopy (FESEM), electron probe micro analyzer (EPMA) and high resolution transmission electron microscopy (HRTEM) assisted X-ray spectroscopy (EDS) and selective area diffraction pattern. Finally microstructures were correlated with the performance of the joint. Diffusion induced intermetallic thickness measured by FESEM image and concentration profile agreed well with the numerically calculated one. HRTEM assisted EDS study was used to identify the large size FeAl{sub 3} and small size Fe{sub 2}Al{sub 5} type intermetallic compounds at the interface. The growth of these two phases in A2 (heat input: 182 J mm{sup −1}) is attributed to the slower cooling rate with higher diffusion time (~ 61 s) along the interface in comparison to the same for A1 (heat input: 155 J mm{sup −1}) with faster cooling rate and shorter diffusion time (~ 24 s). The joint efficiency as high as 65% of steel base metal is achieved for A2 which is the optimized parameter in the present study. - Highlights: • AA 6061 and HIF-GA could be successfully joined by MIG brazing. • Intermetallics are exclusively studied and characterized by XRD, FESEM and EPMA. • Intermetallic formation by diffusion is worth considering or not. • HRTEM-EDS, SAD pattern identifies the morphologies and size of intermetallics. • A compromise concerning formation of IMC is necessary.},
doi = {10.1016/J.MATCHAR.2015.12.030},
journal = {Materials Characterization},
number = ,
volume = 112,
place = {United States},
year = {Mon Feb 15 00:00:00 EST 2016},
month = {Mon Feb 15 00:00:00 EST 2016}
}