A Sound Dissimilar AA5052/S45C Joint Formed by Uniform and Simultaneous Deformation of Both Materials Using Pressure-controlled Joule Heat Forge Welding

Abstract

The effect of weld parameters on the microstructure and mechanical properties of AA5052/S45C dissimilar joints fabricated by a novel pressure-controlled joule heat forge welding (PJFW) was systematically investigated. The deformation behaviors of the materials during the welding process were able to be controlled by regulating the electrical resistance which affects the heating rate. Since the welding temperature decreased with the increasing applied pressure, the formation of the intermetallic compounds layer at the weld interface was suppressed. Thus, a peak joint efficiency of 85% was reached by applying a high pressure of 180 MPa.