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<p>Dissimilar welding of galvannealed steel and aluminum alloys remains a critical challenge in automotive lightweighting due to zinc (Zn) coating-induced interfacial complexities. This study integrates smoothed particle hydrodynamics (SPH) modeling with vaporizing foil actuator welding (VFAW) experiments to unravel the role of Zn coatings in A6451-SGACC steel joint performance. Computational simulations, upon comparison with SEM and EDS results, reveal how localized Zn melting and jetting dynamics govern interfacial heterogeneity, correlating with experimental observations of retained Zn layers, trapped oxides, and incomplete metallurgical bonding. SPH-based predictive modeling elucidates how jet-induced stripping, melt backflow, and vaporization govern zinc transport during high-velocity impact. Clean-bonded regions exhibit complete zinc ejection and sharp Al-Fe contact, enabling a mean lap-shear peak load of 6.32 kN, whereas Zn-rich interlayers suppress interfacial waviness and initiate cross-tension failure with a mean cross-tension peak load of 0.92 kN, corresponding to an ~ 85% reduction relative to lap-shear. SPH modeling accurately captures zinc bilayer dynamics and highly localized temperature spikes (&gt;&#xa0;900 K) confined to the jetting/impact-front region, i.e., ~ 170% higher than the surrounding interface, validating experimental observations. These insights address a critical gap in joining coated dissimilar materials and inform the design of reliable, lightweight automotive structures.</p>

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Computational and Experimental Insights into Zinc-Coating Dynamics for Dissimilar Impact Welding of Galvannealed Steel-Aluminum Joints

  • 期刊论文

  • 发表日期：

    2026年2月6日

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  • Deepak Kumar,
  • Jungyu Choi,
  • Hyeonbeom Lim,
  • Hyuckmin Kwon,
  • Junyeong Jeong,
  • Yongshin Kim,
  • Taeseon Lee

摘要

Dissimilar welding of galvannealed steel and aluminum alloys remains a critical challenge in automotive lightweighting due to zinc (Zn) coating-induced interfacial complexities. This study integrates smoothed particle hydrodynamics (SPH) modeling with vaporizing foil actuator welding (VFAW) experiments to unravel the role of Zn coatings in A6451-SGACC steel joint performance. Computational simulations, upon comparison with SEM and EDS results, reveal how localized Zn melting and jetting dynamics govern interfacial heterogeneity, correlating with experimental observations of retained Zn layers, trapped oxides, and incomplete metallurgical bonding. SPH-based predictive modeling elucidates how jet-induced stripping, melt backflow, and vaporization govern zinc transport during high-velocity impact. Clean-bonded regions exhibit complete zinc ejection and sharp Al-Fe contact, enabling a mean lap-shear peak load of 6.32 kN, whereas Zn-rich interlayers suppress interfacial waviness and initiate cross-tension failure with a mean cross-tension peak load of 0.92 kN, corresponding to an ~ 85% reduction relative to lap-shear. SPH modeling accurately captures zinc bilayer dynamics and highly localized temperature spikes (> 900 K) confined to the jetting/impact-front region, i.e., ~ 170% higher than the surrounding interface, validating experimental observations. These insights address a critical gap in joining coated dissimilar materials and inform the design of reliable, lightweight automotive structures.