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<p>The dissimilar joining of aluminum alloys to steels remains a significant challenge due to the formation of brittle intermetallic compounds (IMCs) and poor wettability at the interface. In this work, an induction heating-assisted laser weld-brazing approach is proposed and demonstrated for the first time to fabricate high-performance AA5052/304 stainless steel joints using Zn–Al filler wire. The influence of induction current (0–800 A) on interfacial reaction behavior, IMC evolution, and mechanical properties of the joints is systematically investigated. Results show that induction markedly enhances the wetting and spreading behavior of the molten aluminum, as evidenced by a 33% increase in fusion zone (FZ) width and a 34% reduction in contact angle. At lower induction (0–600 A), the interface is composed primarily of brittle Fe₂Al<sub>5-x</sub>Zn<sub>x</sub> and FeAl<sub>3-x</sub>Zn<sub>x</sub> phases. However, at 800 A, a new ductile intermetallic phase, (Fe, Cr, Ni)<sub>3</sub>(Al, Zn), is observed adjacent to the steel substrate. First-principles density functional theory (DFT) calculations confirm the phase stability and suggest its structure is a variant of Fe₃Al with partial solute incorporation of Cr, Ni, and Zn. Despite limited IMC layer thickening (from 0.55&#xa0;μm to 0.87&#xa0;μm), the joint mechanical performance improves significantly due to the combined effects of enhanced interfacial wetting, refined IMC morphology, and favorable phase transformation. The joint exhibits a peak liner fracture load (LFL) of 316.5 N/mm and a displacement of 3.8&#xa0;mm when using a current of 800 A, representing a transition in fracture mode from brittle interfacial failure to ductile FZ failure.</p>

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Simultaneous enhancement in strength and ductility of dissimilar laser aluminum alloy/steel joints assisted by induction heating

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Chunzhi Ying,
  • Jin Yang,
  • Feifan Wang,
  • Lingqing Wu,
  • Tianyu Dou,
  • Yijian Zeng,
  • Min Zheng,
  • J. P. Oliveira,
  • Jiajia Shen,
  • Jian Ma,
  • Jie Hu

摘要

The dissimilar joining of aluminum alloys to steels remains a significant challenge due to the formation of brittle intermetallic compounds (IMCs) and poor wettability at the interface. In this work, an induction heating-assisted laser weld-brazing approach is proposed and demonstrated for the first time to fabricate high-performance AA5052/304 stainless steel joints using Zn–Al filler wire. The influence of induction current (0–800 A) on interfacial reaction behavior, IMC evolution, and mechanical properties of the joints is systematically investigated. Results show that induction markedly enhances the wetting and spreading behavior of the molten aluminum, as evidenced by a 33% increase in fusion zone (FZ) width and a 34% reduction in contact angle. At lower induction (0–600 A), the interface is composed primarily of brittle Fe₂Al5-xZnx and FeAl3-xZnx phases. However, at 800 A, a new ductile intermetallic phase, (Fe, Cr, Ni)3(Al, Zn), is observed adjacent to the steel substrate. First-principles density functional theory (DFT) calculations confirm the phase stability and suggest its structure is a variant of Fe₃Al with partial solute incorporation of Cr, Ni, and Zn. Despite limited IMC layer thickening (from 0.55 μm to 0.87 μm), the joint mechanical performance improves significantly due to the combined effects of enhanced interfacial wetting, refined IMC morphology, and favorable phase transformation. The joint exhibits a peak liner fracture load (LFL) of 316.5 N/mm and a displacement of 3.8 mm when using a current of 800 A, representing a transition in fracture mode from brittle interfacial failure to ductile FZ failure.