Formation and Toughening Mechanisms of Dispersions in Interfacial Intermetallics of Dissimilar Laser Al/Steel Joints

The key to improve the strength of Al/steel dissimilar joint is to toughen the hard and brittle interfacial intermetallics. Introducing soft and tough dispersions into the interfacial intermetallics would be a promising method. In the present study, Zn-Al alloy (Zn-22Al) was used as the filler metal to generate dispersions in the interfacial intermetallics matrix of dissimilar laser Al/steel joint. The results have shown that soft and tough dispersions, i.e., FeZn10, Al-rich amorphous phase, and Zn solid solution, were successfully introduced into the hard and brittle Fe2Al5−xZnx matrix. The formation of these dispersions was resulted from diffusion of elements Fe and Al and infiltration of liquid Zn along the grain boundaries of Fe2Al5−xZnx matrix and the subsequent chemical reaction and solidification. With this kind of interfacial microstructure, the joint exhibited a stable peak fracture load of 1200 N even though the interfacial layer thickness increased from 20 to 45 μm. This was because the interfacial layer was toughened by the soft and tough dispersions. Using this example, introduction of soft and tough dispersions into hard and brittle intermetallics matrix to toughen interfacial layer and then strengthening of dissimilar joints will be highlighted.