Fe–Al intermetallic suppression of dissimilar RSW joints using stainless-steel interlayers
Bryan Lara, Rafael Arthur Reghine Giorjão, Hassan Ghassemi-Armaki, Antonio J. Ramírez
Abstract
Austenitic and ferritic stainless-steel interlayers for resistance spot welding of an AlSi-coated 2000MPa UTS press-hardened boron steel and a 6022-T4 aluminium alloy were investigated to improve joint performance. CALPHAD and kinetic-based simulations were explored to determine the effects of Cr on the formation of Fe–Al intermetallic compounds. Selected area diffraction reveals the formation of FeCrAl 9 along the interlayer-Al interface and suppresses the formation of FeAl 3 . The implementation of stainless-steel interlayers significantly improved the mechanical performance of the joint, with the 430 foil condition experiencing a substantial decrease in the Fe–Al intermetallic.