It was known that it is challenging to join lapped aluminum and bare steel with cold metal transfer (CMT) process because of the formation of significant brittle intermetallics. In this study, another attempt was made to join aluminum AA6061-T6 and bare mild steel with CMT plug welding. Welding tests were performed and the bonding mechanisms, fracture modes, and strengths of CMT plug welded joints were systematically characterized. It was found that it is feasible to join 1 mm thick bare mild steel-to-1 mm thick aluminum AA6061-T6. The material stacking sequence and the presence of a predrilled hole significantly affected the weldability of CMT plug welding bare mild steel-to-aluminum AA6061-T6. By positioning bare steel with a predrilled hole in the top aluminum AA6061-T6 and aligning a torch in the center of an 8 mm hole improved significantly the weld appearance and joint strength.
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August 2016
Research-Article
Cold Metal Transfer Plug Welding of Aluminum AA6061-T6-to-Bare Mild Steel
R. Cao,
R. Cao
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: caorui@lut.cn
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: caorui@lut.cn
Search for other works by this author on:
Q. Huang,
Q. Huang
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 852776916@qq.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 852776916@qq.com
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C. Z. Zeng,
C. Z. Zeng
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 1277010498@qq.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 1277010498@qq.com
Search for other works by this author on:
B. Q. Ai,
B. Q. Ai
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 983616454@qq.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 983616454@qq.com
Search for other works by this author on:
Q. Lin,
Q. Lin
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: lqllinqiaoli@163.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: lqllinqiaoli@163.com
Search for other works by this author on:
J. H. Chen,
J. H. Chen
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: zchen@lut.cn
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: zchen@lut.cn
Search for other works by this author on:
Pei-Chung Wang
Pei-Chung Wang
Manufacturing Systems Research Laboratory,
General Motors Global Research and
Development Center,
MC 480-106-RA2,
30500 Mound Road,
Warren, MI 48090
e-mail: pei-chung.wang@gm.com
General Motors Global Research and
Development Center,
MC 480-106-RA2,
30500 Mound Road,
Warren, MI 48090
e-mail: pei-chung.wang@gm.com
Search for other works by this author on:
R. Cao
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: caorui@lut.cn
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: caorui@lut.cn
Q. Huang
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 852776916@qq.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 852776916@qq.com
C. Z. Zeng
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 1277010498@qq.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 1277010498@qq.com
B. Q. Ai
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 983616454@qq.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: 983616454@qq.com
Q. Lin
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: lqllinqiaoli@163.com
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: lqllinqiaoli@163.com
J. H. Chen
State Key Laboratory of Advanced Processing and
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: zchen@lut.cn
Recycling of Non-Ferrous Metals,
Lanzhou University of Technology,
Langongping 287 Road,
Qilihe District,
Lanzhou, Gansu 730050, China
e-mail: zchen@lut.cn
Pei-Chung Wang
Manufacturing Systems Research Laboratory,
General Motors Global Research and
Development Center,
MC 480-106-RA2,
30500 Mound Road,
Warren, MI 48090
e-mail: pei-chung.wang@gm.com
General Motors Global Research and
Development Center,
MC 480-106-RA2,
30500 Mound Road,
Warren, MI 48090
e-mail: pei-chung.wang@gm.com
Manuscript received August 1, 2015; final manuscript received March 10, 2016; published online April 7, 2016. Assoc. Editor: Wayne Cai.
J. Manuf. Sci. Eng. Aug 2016, 138(8): 081008 (12 pages)
Published Online: April 7, 2016
Article history
Received:
August 1, 2015
Revised:
March 10, 2016
Citation
Cao, R., Huang, Q., Zeng, C. Z., Ai, B. Q., Lin, Q., Chen, J. H., and Wang, P. (April 7, 2016). "Cold Metal Transfer Plug Welding of Aluminum AA6061-T6-to-Bare Mild Steel." ASME. J. Manuf. Sci. Eng. August 2016; 138(8): 081008. https://doi.org/10.1115/1.4033040
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