O. Seffer
A. Springer
S. Kaierle

Remote Laser Beam Welding of Different, Dissimilar Steel and Aluminum Alloys with Varying Sheet Thicknesses for Automotive Lightweight Construction

Proc. International Congress on Applications of Lasers & Electro-Optics (ICALEO)
Type: Zeitschriftenaufsatz (reviewed)
For lightweight construction, different steel and aluminum materials with various thicknesses can be welded together, depending on the dimensions and the individual functions of the workpiece. Especially for frame and body construction, remote laser beam welding has been established as a suitable and efficient joining method for similar material seams for several years. In contrast to joining similar materials, thermal joining of steel and aluminum alloys includes different technological challenges due to the formation of hard and brittle intermetallic phases, which decrease the strength and the formability of the dissimilar joints. In the context of these requirements, the presented results show, besides the influence of different steel materials, particularly the influence of different sheet thicknesses, respectively thickness ratios on the appropriate process parameters for remote laser beam welded lap joints of steel and aluminum alloys. Different thickness ratios, process parameters and material properties affect the geometrical formation of the weld seam regarding penetration depth~tE and weld width~b, which mainly influences the composition of the molten bath, and accordingly the transmittable forces. Within the scope of the presented investigations, dissimilar joints of the steel materials HX220LAD+Z100, 22MnB5+AS150 and 1.4301, as well as the aluminum alloy AA6016T4 are characterized. Among other things, the influences of energy per unit length, material grade and sheet thickness ratio on the achievable strengths were analyzed. The characterization of the dissimilar joints includes tensile shear tests and metallographic analyses, depending on the energy per unit length.