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Effect of Zinc Coatings on Joint Properties and Interfacial Reactions in Aluminum to Steel Ultrasonic Spot Welding

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Abstract

Dissimilar joining of aluminum to steel sheet in multimaterial automotive structures is an important potential application of ultrasonic spot welding (USW). Here, the weldability of different zinc-coated steels with aluminum is discussed, using a 2.5-kW USW welder. Results show that soft hot-dipped zinc (DX56-Z)-coated steel results in better weld performance than hard (galv-annealed) zinc coatings (DX53-ZF). For Al to hard galv-annealed-coated steel welds, lap shear strengths reached a maximum of ~80% of the strength of an Al-Al joint after a 1.0 s welding time. In comparison, welds between Al6111-T4 and hot dipped soft zinc-coated steel took longer to achieve the same maximum strength, but nearly matched the Al-Al joint properties. The reasons for these different behaviors are discussed in terms of the interfacial reactions between the weld members.

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Acknowledgements

The authors would like to thank M. Shergold of JLR and A. Smith of Corus for provision of materials. We are also grateful to the EPSRC for funding this research through; LATEST2 (EP/G022402/1), and Friction Joining – Low Energy Manufacturing for Hybrid Structures in Fuel Efficient Transport Applications, EP/G022402/1.

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Authors and Affiliations

  1. School of Materials, The University of Manchester, Manchester, M13 9PL, UK

    F. Haddadi, D. Strong & P. B. Prangnell

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  1. F. Haddadi
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  2. D. Strong
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  3. P. B. Prangnell
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Correspondence to F. Haddadi.

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Haddadi, F., Strong, D. & Prangnell, P.B. Effect of Zinc Coatings on Joint Properties and Interfacial Reactions in Aluminum to Steel Ultrasonic Spot Welding. JOM 64, 407–413 (2012). https://doi.org/10.1007/s11837-012-0265-9

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  • DOI: https://doi.org/10.1007/s11837-012-0265-9

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