| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
|
| Symposium
|
Solid-State Diffusion Bonding of Metals and Alloys
|
| Presentation Title |
Ultrasonic Metal Welding of Interlayers to Improve Joint Performance of Aluminum to Steel Resistance Spot Welds in Automotive Applications |
| Author(s) |
Rakhi Bawa, Antonio Ramirez, Kelly Osborn, Kaue Riffel |
| On-Site Speaker (Planned) |
Rakhi Bawa |
| Abstract Scope |
The increased interest in vehicle lightweighting has led to a surge in the use of advanced high strength steels and aluminum alloys in vehicle design. Advanced high strength steels provide high crashworthiness and design flexibility, while aluminum provides strength and has lightweight characteristics. Joining of these materials is accomplished by resistance spot welding (RSW), however this dissimilar joining results in brittle intermetallic phases which degrade joint performance. To mitigate these brittle phases, the use of interlayers has been explored to limit contact between the base metals. In this study, ultrasonic metal welding of stainless-steel interlayers to aluminum prior to the dissimilar RSW is optimized to improve joint performance by limiting the formation of intermetallic phases. Mechanical testing is conducted to evaluate the interlayer deposition method and overall weld performance. In addition, microstructure analysis of the joints shows a limited growth of the intermetallic phases as compared to the no-interlayer condition. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Joining, Mechanical Properties, |