Microstructure and Mechanical Properties of Galvanized Steel/AA6061 Joints by Laser Fusion Brazing Welding

doi:10.1007/s40195-014-0091-x

Abstract

Abstract:

Laser fusion brazing welding was proposed. Galvanized steel/AA6061 lapped joint was obtained by laser fusion brazing welding technique using the laser-induced aluminium molten pool spreading and wetting the solid steel surface. Wide joint interface was formed using the rectangular laser beam coupled with the synchronous powder feeding. The result showed that the tiny structure with the composition of α-Al and Al–Si eutectic was formed in the weld close to the Al side. And close to the steel side, a layer of compact Fe–Al–Si intermetallics, including the Al-rich FeAl₃, Fe₂Al₅ phases and Al–Fe–Si τ1 phase, was generated with the thickness of about 10–20 μm. Transverse tensile shows the brittle-fractured characteristic along to the seam/steel interface with the maximum yield strength of 152.5 MPa due to the existence of hardening phases τ1 and Al–Fe intermetallics.

Key words: Galvanized steel, Aluminium alloy, Laser welding, Interface, Microstructural characterization, Mechanical property

Junxia Lü, Wuxiong Yang, Shikai Wu, Xudong Zhao, Rongshi Xiao. Microstructure and Mechanical Properties of Galvanized Steel/AA6061 Joints by Laser Fusion Brazing Welding[J]. Acta Metallurgica Sinica (English Letters), 2014, 27(4): 670-676.

Figures/Tables 11

Table 1 Mechanical properties of the base metals

Material	Tensile strength (MPa)	Yield strength (MPa)	Elongation (%)
AA6061-T6	280	230	8–15
Galvanized steel	395	350	35

Table 2 Chemical compositions of AA6061, low carbon steel, filler power, solder, and galvanized layer

Material	Si	Fe	Cu	Mn	Mg	Cr	Zn	Ti	Al
AA6061	0.52	0.5	0.18	0.09	0.84	0.22	0.16	0.13	Bal.
Filler powder	12	–	–	–	–	–	–	–	Bal.
BAl₈₈Si	12	–	–	–	–	–	–	–	Bal.

Material	C	Si	P	S	Mn	Fe	Ni	Zn	–
Carbon steel	0.08	0.03	0.025	0.02	0.40	Bal.	–	–	–
Galvanization	–	–	–	–	–	–	10–15	Bal.	–

Fig. 1 Schematic illustration of welding experimental setup: a side view; b front view; c diagram of the tensile test specimen

Fig. 2 a Energy distribution of the rectangular laser spot; b powder stream configuration of rectangular broadband nozzle

Fig. 3 Cross section of a galvanized steel/AA6061 joint showing the whole joint macromorphology a, microstructures of position A b, B c in a, the magnified image of zone E in c is shown in d (P = 2.0 kW, V = 0.12 m/min, Δf = +20 mm)

Table 3 Chemical elements content at different positions in weld (at%)

Position	Al	Mg	Si
1	93.86	0.78	4.61
2	94.1	0.69	5.21
3	93.86	–	6.14
4	85.67	–	14.33

Fig. 4 TEM images of the interfacial region in the galvanized steel-AA6061: aP = 4.0 kW, V = 0.12 m/min, Δf = +30 mm; bP = 3.0 kW, V = 0.3 m/min, Δf = +20 mm; cP = 2.0 kW, V = 0.12 m/min, Δf = +20 mm; d HRTEM of c

Fig. 5 Microhardness profile across the galvanized steel-AA6061 joint

Fig. 6 Macro-fracture image of the tensile-shear specimen for galvanized steel-AA6061 lapped joint: a macroscopic fractured morphology; b microsturctue of fractured section

Fig. 7 Cross section of the galvanized steel/aluminium interface: details of a compact structure below and the dendritic intermetallics in the upper part (P = 4.0 kW, V = 0.12 m/min, Δf = +20 mm)

Fig. 8 XRD patterns of galvanized steel/Al interface: a scan along to the lower surface of the compact structure; b scan along to the upper surface of the compact structure

References 14

[1]	A. Mathieu, R. Shabadi, A. Deschamps, M. Suery, S. Matteï, D. Grevey, E. Cicala, Opt. Laser Technol. 39, 652(2007)10.1016/j.optlastec.2005.08.014
[2]	S.B. Lin, J.L. Song, G.C. Ma, C.L. Yang, Front. Mater. Sci. China 3, 78(2009)10.1007/s11706-009-0007-2
[3]	E. Taban, J.E. Gould, J.C. Lippold, Mater. Des. 31, 2305(2010)10.1016/j.matdes.2009.12.010
[4]	P. Peyre, G. Sierra, F. Deschaux-Beaume, D. Stuart, G. Fras, Mater. Sci. Eng. A 444, 327(2007)10.1016/j.msea.2006.09.111
[5]	M. Kreimeyer, G. Sepold, inProceedings of the International Congress on Applications of Lasers and Electro-Optics (ICALEO)(Laser Institute of America, Jacksonville, 2002)
[6]	M.J. Rathod, M. Kutsuna, Weld. J. 83, 16(2004)
[7]	G. Sierra, P. Peyre, F. Deschaux-Beaume, D. Stuart, F. Coste, G. Fras, inThe International Congress on Applications of Lasers and Electro-Optics (ICALEO)(Laser Institute of America, San Francisco, 2004)
[8]	S. Katayama, M. Mizutani, inThe International Congress on Applications of Lasers and Electro-Optics (ICALEO), (Laser Institute of America, Jacksonville, 2003)
[9]	G. Sierra, P. Peyre, F. Deschaux-Beaume, D. Stuart, G. Fras, Mater. Sci. Eng. A 447, 197(2007)10.1016/j.msea.2006.10.106
[10]	X.D. Zhao, R.S. Xiao, K. Chen, inThe International Congress on Applications of Lasers and Electro-Optics (ICALEO)(Laser Institute of America, Orlando, 2009)
[11]	X.D. Zhao, R.S. Xiao, K. Chen, Chin. J. Lasers 39, 0403004(2012)10.3788/CJL201239.0403004
[12]	S.P. Gupta, Mater. Charact. 49, 269(2003)10.1016/S1044-5803(03)00006-8
[13]	D. Naoi, M. Kajihara, Mater. Sci. Eng. A 459, 375(2007)10.1016/j.msea.2007.01.099
[14]	N. Krendelsberger, F. Weitzer, J.C. Schuster, Metall. Mater. Trans. A 38, 1681(2007)10.1007/s11661-007-9182-x

[1]	Shuyi Ren, Jiao Li, Kai Wu, Xiaoge Li, Yaqiang Wang, Jinyu Zhang, Gang Liu, Jun Sun. Thermal Stability and Mechanical Properties of Nanotwinned Ni-W Alloyed Films [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(9): 1570-1582.
[2]	Yunlu Jiang, Lihui Wu, Dingrui Ni, Hongbo Zhao, Xu Han, Peng Xue, Bolv Xiao, Zongyi Ma. Effect of Post Weld Heat Treatment on Residual Stress and Mechanical Properties of 106 mm Thick TC4 Titanium Alloy Electron Beam Welded Joints [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(7): 1083-1094.
[3]	Tiantian Wang, Lin Liu, Zexin Liu, Kang Wang, Runhua Yao, Xiaohong Yao, Ruiqiang Hang. Characterization, Mechanical Property, Degradation Behavior, and Osteogenic Activity of Zn-Mn Alloy Foam Prepared by Electrodeposition [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(7): 1157-1173.
[4]	Yunhu Ding, Yingpeng Li, Hongfang Liu, Wenhao Wang, Yijun Wei, Haitao Duan, Wen Zhan. Corrosion Evolution Behavior of Ti/Zr/Oligomeric Epoxy Silane Composite Chemical Conversion Coatings on Multi-metals [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(6): 889-903.
[5]	Chenzhi Xing, Ming-Hsien Lee, Gongwang Cao, Yuwei Liu, Quanzhong Guo, Zhenyao Wang, Chuan Wang. Discoloration Process of Minted Copper-Nickel Alloys in Chloride Ion-Containing Environments: Experimental and DFT Research [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(6): 925-945.
[6]	Yifan Li, Shengyao Ma, Xinrui Zhang, Tong Xi, Chunguang Yang, Hanyu Zhao, Ke Yang. Copper Precipitation Behavior and Mechanical Properties of Cu-Bearing Ferritic Stainless Steel with Different Cr Addition [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(3): 383-395.
[7]	Hongbin Liu, Zhenqiang Xing, Yitong Yang, Jingyu Pang, Wen Li, Zhengwang Zhu, Long Zhang, Aimin Wang, Haifeng Zhang, Hongwei Zhang. A Novel BCC/B2 Structural Nb₃₈Ti₃₅Al₁₅V₆Cr₄(TaHfMoW)₂ Refractory High-Entropy Alloy with Excellent Specific Yield Strength-Plasticity Synergy [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(3): 396-406.
[8]	Huajian Wu, Jieli Ma, Yong Jiang, Yiren Wang, Fuhua Cao. Roles of Y₂Zr₂O₇ Nano-Oxides in Helium Management in ODS Ferritic Alloys: A First-Principles Study [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(3): 497-506.
[9]	Zhiqing Chen, Zhixian Zhao, Yiqiang Hao, Xiaoling Chen, Liping Zhou, Jingya Wang, Tao Ying, Bin Chen, Xiaoqin Zeng. Development of Interpenetrating Phase Structure AZ91/Al₂O₃ Composites with High Stiffness, Superior Strength and Low Thermal Expansion Coefficient [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 245-258.
[10]	Weize Lv, Guowei Zhang, Heqian Song, Dan Zhang, Shiyuan Liu, Hong Xu. Effect of Rotating Magnetic Field on the Microstructure and Shear Property of Al/Steel Bimetallic Composite by Compound Casting [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 276-286.
[11]	Wei Qiu, Shuang-Long Li, Zhao-Yuan Lu, Sen-Mao Zhang, Jian Chen, Wei Chen, Lang Gan, Wei Li, Yan-Jie Ren, Jun Luo, Mao-Hai Yao, Wen Xie. Effects of CeO₂ Content on the Microstructure and Mechanical Properties of ZK60 Mg Alloy [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 287-298.
[12]	Dongfang Lou, Mingda Zhang, Yuping Ren, Hongxiao Li, Gaowu Qin. Fabrication of Zn-0.5Mn-0.05 Mg Micro-Tube with Suitable Strength and Ductility for Vascular Stent Application [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 327-337.
[13]	Lingyi Kong, Xingpu Zhang, Pengfei Yue, Wanshun Xia, Zhe Hong, Xinbao Zhao, Jiangwei Wang, Ze Zhang. Characterization of σ/Matrix Interface in Ni-Based Single Crystal Superalloys [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(12): 2115-2124.
[14]	Yao-Zong Mao, Ya-Hui Zhang, De-Chun Ren, Diao-Feng Li, Hai-Bin Ji, Hai-Chang Jiang, Chun-Guang Bai. Effect of Process Parameters on the Microstructure and Properties of Ti15Zr5Cu Alloy Fabricated via Selective Laser Melting [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(10): 1699-1710.
[15]	Fang-Fang Cao, Cui-Ju Wang, Kai-Bo Nie, Quan-Xin Shi, Yi-Jia Li, Kun-Kun Deng. Mechanical Properties and Work Hardening Behavior of Ti_p/Mg-Gd-Y-Zn Composites [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(10): 1777-1793.