Microstructure and Properties of Resistance Element Welded Joints of DP780 Steel and 6061 Aluminum Alloy

• Published in: Metals (Basel ) Vol. 15; no. 3; p. 283
• Main Authors: Wu, Qinglong, Yang, Yue, Li, Yingzhe, Guo, Qing, Luo, Shuyue, Luo, Zhen
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.03.2025
• Subjects: Alloys; Aluminum; aluminum alloy; Aluminum alloys; Aluminum base alloys; Automobile industry; Dissimilar material joining; Dissimilar metals; DP780 steel; Dual phase steels; Electrodes; Electron back scatter; Electron probe microanalysis; failure mode; Failure modes; High strength steels; Intermetallic compounds; Investigations; Martensite; Mechanical properties; Microhardness; Microstructure; Morphology; resistance element welding; Solidification; Specialty metals industry; Spectrum analysis; Steel; Thickness; Welded joints; Welding; Welding current; China; Japan

This study developed a metallurgical and mechanical hybrid resistance element welding (REW) method to fabricate lightweight Al/steel joints between 2.0 mm 6061 aluminum alloy and 1.2 mm DP780 steel, addressing critical challenges of interfacial intermetallic compounds (IMC layer thickness: 4.6–8.3 μ...