Al heat affected zone-less resistance element welded lap joints of Al alloy and 1 GPa class steel: Transition of microstructure and fracture with heat transfer

In this study, Al joint systems without heat-affected zones (HAZ) were developed on Al/Fe alloy lap joints fabricated by resistance element welding (REW). The robustness of the joints with and without HAZs was quantitatively evaluated to consider another side effect in REW Al/Fe alloy systems. Compared to conventional REW, removing the Al HAZ not only alters the steel properties, but also reduces the work hardening of the Al alloy due to the difference in the distinct heat transfer paths. Furthermore, the presence of Al HAZ significantly influenced the hardness characteristics of the molten steel portion. In the cold wall configuration without Al HAZ, hardness values exceeding those of the hot wall by approximately 100 Hv or more were observed. At a welding current of 10.5 kA, the hot wall configuration demonstrated an approximate 30 % increase in tensile shear load and a 66 % increase in displacement compared to the cold wall configuration without HAZ. In the cold wall conditions, interfacial failure (IF) was not attributed to microstructural disparities but was linked to the formation of an inherent notch root when S20C melted due to the absence of Al HAZ. Contrary to previous reports, the presence of HAZ in Al alloys results the production of tough steel through REW.