Fluxless arc weld-brazing of aluminium alloy to steel

In this work, joining of aluminium alloy AA6061-T6 to Interstitial Free steel using pulsed gas metal arc welding process has been attempted. The effect of different surface conditions of steel (viz, galvanized, galvanealed and uncoated) and gap between the sheets on braze joint formation have been investigated. Galvanized steel surface showed good bead width, joint formation and lap shear strength compared to the other two combinations. Interface gap has not affected the wetting behaviour significantly but presence of a gap of 300 μm or so helped in escape of zinc vapour during the process there by avoiding formation of any crevice or macroporosity in the joint. Features and properties of the joint are characterized by metallography, fractography, energy dispersive spectroscopy (EDS) and lap shear tests. Load carrying capacity of Al-Galvanized steel was highest (222 N/mm of seam length) compared to other combinations, aided by better wetting due to presence of Zn on the surface and minimum porosity due to interfacial gap provided during brazing.