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Controlling Interfacial Reaction in Aluminium to Steel Dissimilar Metal Welding

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Controlling Interfacial Reaction in Aluminium to Steel Dissimilar Metal Welding Controlling Interfacial Reaction in Aluminium to Steel Dissimilar Metal Welding A thesis submitted to the University of Manchester for the degree of Doctor of Philosophy in the faculty of Engineering and Physical Sciences 2015 Lei Xu School of Material Content CONTENTS List of Figures ......................................................................................................................... 6 List of Tables ......................................................................................................................... 21 List of Publications ............................................................................................................... 22 Abstract ................................................................................................................................ 23 Declaration ........................................................................................................................... 24 Copyright .............................................................................................................................. 25 Acknowledgements .............................................................................................................. 26 Chapter 1 Introduction ......................................................................................................... 27 1.1 State of the Art and Motivation ................................................................................. 27 1.1.1 Greenhouse Gas Emissions ................................................................................. 27 1.1.2 Light Weighting ................................................................................................... 29 1.1.3 Welding Methods ................................................................................................ 31 1.2 Objectives of the Study .............................................................................................. 34 1.3 Thesis Overview ......................................................................................................... 35 Chapter 2 Literature Review ................................................................................................ 37 2.1 Introduction ............................................................................................................... 37 2.2 The Principles of Welding........................................................................................... 37 2.3 Welding Techniques ................................................................................................... 39 2.3.1 Fusion Welding .................................................................................................... 40 2.3.2 Solid State Welding ............................................................................................. 47 2.4 Base Material ............................................................................................................. 68 2.4.1 Aluminium Alloy .................................................................................................. 68 2.4.2 Low Carbon Automotive Steel ............................................................................ 70 2.5 Intermetallic Compounds ........................................................................................... 71 2.5.1 Crystallographic Structures of η and θ Phases ................................................... 72 2 Content 2.5.2 The Evolution of the IMC Layer ........................................................................... 75 2.5.3 Microstructure of the IMC Layers ....................................................................... 79 2.5.4 Growth Kinetics of the IMC Layer ....................................................................... 82 2.6 Summary .................................................................................................................... 90 Chapter 3 Experimental Methods ........................................................................................ 93 3.1 Parent Materials ......................................................................................................... 93 3.2 Ultrasonic Spot Welding ............................................................................................. 94 3.3 Friction Stir Spot Welding .......................................................................................... 97 3.4 Temperature Measurement ...................................................................................... 99 3.5 Metallographic Sample Preparation ........................................................................100 3.6 Heat Treatment ........................................................................................................101 3.7 Lap Shear Testing .....................................................................................................103 3.8 Hardness Testing ......................................................................................................103 3.9 Surface Profile ..........................................................................................................106 3.10 Scanning Electron Microscope (SEM) ....................................................................106 3.10.1 Scanning Electron Microscope (SEM) .............................................................106 3.10.2 Energy Dispersive X-ray (EDX) .........................................................................108 3.10.3 Electron Backscatter Diffraction (EBSD) .........................................................108 3.11 Focused Ion Beam (FIB) Milling ..............................................................................109 3.12 Transmission Electron Microscope (TEM) .............................................................111 3.13 Image Analysis ........................................................................................................114 Chapter 4 Weld formation and interface layer in Fe-Al dissimilar joints ..........................116 4.1 Introduction .............................................................................................................116 4.2 Parent Sheet Surface Condition ...............................................................................117 4.3 The Microstructure And Mechanical Properties Of Fe-Al Dissimilar Joints Made By USW ................................................................................................................................118 3 Content 4.3.1 Temperature Histories Of The USW Joints .......................................................118 4.3.2 Weld Characterization ......................................................................................119 4.3.3 Analysis of the Joint Interfaces .........................................................................120 4.3.4 Lap Shear Testing ..............................................................................................125 4.4 The Development Of The IMC Layer In Fe-Al Dissimilar Joints Made By FSSW .......129 4.4.1 Temperature Histories In Pin-Less FSSW ..........................................................129 4.4.2 Microstructure Of The IMC Layer In The Pin-Less FSSW Joints ........................130 4.4.3 The Interface In The Joints Made By ABC-FSSW ...............................................134 4.5 Discussion .................................................................................................................135 4.5.1 The Effect Of The Alloy Elements On The Phase Composition In Dissimilar Fe-Al Joints ..........................................................................................................................135 4.5.2 Development of the IMC layer at the interface in joints made by USW and FSSW ...........................................................................................................................136 4.5.3 The Different Growth Rates Of The IMC Layer During The Two Welding Processes ....................................................................................................................143 4.5.4 Relationship Between Interfacial Microstructure And Mechanical Properties Of The USW Joints ...........................................................................................................145 4.6 Summary And Conclusions .......................................................................................148 Chapter 5 The static growth behaviour of intermetallic compounds in steel and aluminium dissimilar welds ..................................................................................................................150 5.1 Introduction .............................................................................................................150 5.2 The Influence Of The Initial State On The IMC Layer During Heat Treatment ........151 5.2.1 The Microstructure Development Of The IMC Layer In The ABC-FSSW Joints During Annealing ........................................................................................................151 5.2.2 The Microstructure Of The IMC Layer In The USW Joints After Annealing ......157 5.2.3 The Development Of The Grain Structure In The IMC Layer ............................161 5.2.4 The Growth Kinetics Of The IMC Layer .............................................................164 4 Content 5.3 The Influence Of Zinc On The IMC Layers During Heat Treatment..........................168 5.4 Discussion .................................................................................................................170
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