Numerical prediction for temperature and microstructure of A283GRC steel and 5052 aluminium alloy during induction-pressure welding

A finite element model was built to investigate and predict the material properties of A283GRC steel and 5052 aluminium alloy during induction-pressure welding (IPW). The temperature evolution, distribution, uniformity were investigated and the thickness of intermetallic compound was predicted in the case of different processing parameters during the IPW process. The results showed that the IPW can successfully join A283GRC steel and 5052 aluminum alloy. The temperature distribution uniformity on Fe/Al interface can keep above 85% when the metallurgical reaction appeared. The distributions for Fe and Al atoms were uniform on the interface in the case of different powers and gaps. The simulated temperature on the surface and interface as well as intermetallic compound thickness were consistent with the experimental results. The simulated temperature and intermetallic compound thickness errors can be attributed to the gap between steel and aluminum alloy appeared in experiment, which was generated by the heat distortion.