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Welding of aluminium alloys to steels has been always challengeable. There are a certain number of methods to join these dissimilar metals all have their advantages and disadvantages. Advancement of any aluminium to steel welding strategies is an approach to control the size and nature of the intermetallic compound layer. A new method of electro spark microwelding has been developed for dissimilar welding of an aluminium alloy to steel to improve the joint mechanical properties. The microstructure of the welds are investigated by scanning transmission electron microscopy. The maximum tensile strength reached 206 MPa representing 65% of the tensile strength of the parent aluminium alloy with a ductile fracture locating at the fusion zone. The excellent bonding of the aluminium alloy and steel was based on the combined effects of the formation of about 4 μm thick nanoscale Fe rich intermetallic compound layer and complex mechanical inter-locking. The current research confirmed that aluminium could be successfully welded to steel via electro spark microwelding process.

Microstructural Characterization and Mechanical Properties of AA5083 Aluminum to AISI 1018 Steel Welds by Electro Spark Microwelding