Spot Forge-Welding for Rapid Dissimilar Joining of Fe to Al to Produce an Intermetallic Compound-Free Interface

Abstract

To solve the problem in joining dissimilar metals caused by intermetallic compound, dissimilar lap joining of SUS304 and A5083 was examined using a spot forge-welding method. The tensile shear load reached approximately 4.5 kN with a short bonding time of less than 0.1 s. Fatigue data were also acquired to confirm practical strength. The reaction layer of the bonded interface was approximately 10 nm thick, consistent with the calculated value. A high-strength dissimilar joining process that provides a highly productive and virtually intermetallic compound-free interface was established.