Effect of modified flux on MIG arc brazing-fusion welding of aluminum alloy to steel butt joint

Pulsed MIG arc brazing-fusion welding process was applied to realize the butt joining of galvanized steel and 5052 aluminum alloy with no enclosed slot or groove adopted. A modified flux mixture was developed to improve the butt joint performance. After applying the modified flux, weld appearance became better and the spreadability of filler metal was also greatly improved. During brazing-fusion welding process, flux floating on the surface of welding pool weakened the surface tension between filler metal and Fe and reduced the evaporation of Zn, which both led to the greatly enhanced spreadability. The analysis of intermetallic compounds (IMCs) at brazed interface showed that Fe3Al was formed at upper side of steel plate, while Fe2Al5 was formed at other areas with the consideration of its lowest Gibbs free energy under certain temperature range. With modified flux, the tensile strength of the joint could reach up to 120 MPa, which was about 60% of that of 5052 aluminum alloy base metal. From the fractured surface, two different fracture modes were identified, tear fracture and intergranular fracture, which confirmed that joint fractured in a brittle mode. The crack initiated at the front side of brazed interface due to the thicker IMCs layer, then propagated to the surface before the whole joint failed. The improved spreadability of filler metal on the top and back sides of steel plate due to the application of flux, contributed to the improvement of joint strength. (C) 2017 Elsevier B.V. All rights reserved.