Joining steel and aluminum parts combing additive manufacturing process and laser welding

Wolfgang Knapp; Pascal Paillard; Laurent Couturier; Emilie Aubignat

doi:10.1117/12.2547492

2 March 2020 Joining steel and aluminum parts combing additive manufacturing process and laser welding

Wolfgang Knapp, Pascal Paillard, Laurent Couturier, Emilie Aubignat

Proceedings Volume 11273, High-Power Laser Materials Processing: Applications, Diagnostics, and Systems IX; 112730F (2020) https://doi.org/10.1117/12.2547492
Event: SPIE LASE, 2020, San Francisco, California, United States

Abstract

Joining aluminum and steel today is still challenging. The large difference of melting points of Al and Fe and the rapid formation of fragile intermetallic compounds (IM) make the welding of Al-based and Fe-based alloys at most very difficult if not impossible. Nonetheless, the need of such joints is growing since one tends to incorporate more and more aluminum parts as replacement of “low stressed” steel parts in order to achieve lightweight structures, especially in transportation industry. Here the idea is to depose a thick (<<mm) layer of aluminum on the steel using a powder additive manufacturing process: the cold spray. Aluminum powder is blown toward the steel using pressured gas at rather low temperature (around 80°C). The aluminum part is then welded to the additive manufactured aluminum layer on the steel using conventional laser welding. In the second part of this presentation copper deposition using cold spray is used on thin PCB conductors to allow laser welding of connectors.

Citation Download Citation

Wolfgang Knapp, Pascal Paillard, Laurent Couturier, and Emilie Aubignat "Joining steel and aluminum parts combing additive manufacturing process and laser welding", Proc. SPIE 11273, High-Power Laser Materials Processing: Applications, Diagnostics, and Systems IX, 112730F (2 March 2020); https://doi.org/10.1117/12.2547492

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