Abstract
In this review, present status of laser welding/brazing (LWB) of aluminum alloy to steel is adopted in detail. This review shows the current scholarly exploration and achievements in this field through the three aspects of the process, microstructure of intermetallic reaction layer, and mechanical properties. From the selection of laser source, temperature control, and filler metal selection, the technological factors of laser welding applied to Fe/Al dissimilar metal bonding are discussed. We presented the relationship between the microstructure and mechanical properties of the intermetallic reaction layer in the Fe/Al joint by laser welding. To sum up, laser welding/brazing has a broad application prospect in Fe/Al dissimilar metal bonding.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig1_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig3_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig4_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig6_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig7_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig8_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig9_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig10_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-021-06607-4/MediaObjects/170_2021_6607_Fig11_HTML.png)
Similar content being viewed by others
Data availability
The data sets supporting the results of this article are included within the article and its additional files.
References
Liu L, Qi X (2010) Strengthening effect of nickel and copper interlayers on hybrid laser-TIG welded joints between magnesium alloy and mild steel. Mater Des 31(8):3960–3963
Lee W-B, Schmuecker M, Mercardo UA, Biallas G, Jung S-B (2006) Interfacial reaction in steel–aluminum joints made by friction stir welding. Scr Mater 55(4):355–358
Mathieu A, Shabadi R, Deschamps A, Suery M, Matteï S, Grevey D, Cicala E (2007) Dissimilar material joining using laser (aluminum to steel using zinc-based filler wire). Opt Laser Technol 39(3):652–661
Sierra G, Peyre P, Deschaux Beaume F, Stuart D, Fras G (2008) Galvanised steel to aluminium joining by laser and GTAW processes. Mater Charact 59(12):1705–1715
Torkamany MJ, Tahamtan S, Sabbaghzadeh J (2010) Dissimilar welding of carbon steel to 5754 aluminum alloy by Nd:YAG pulsed laser. Mater Des 31(1):458–465
Yang J, Yu Z, Li Y, Zhang H, Guo W, Zhou N (2018) Influence of alloy elements on microstructure and mechanical properties of Al/steel dissimilar joint by laser welding/brazing. Weld World 62(2):427–433
Yu-Dong C, Mei-Han W, Ming-Huei S, Cheng-Yen C (2009) Myocardial bridging in Taiwan: depiction by multidetector computed tomography coronary angiography. J Formos Med Assoc 108:469–474
Chen S, Li L, Chen Y, Dai J, Huang J (2011) Improving interfacial reaction nonhomogeneity during laser welding–brazing aluminum to titanium. Mater Des 32(8–9):4408–4416
Zhao S, Yu G, He X, Hu Y (2012) Microstructural and mechanical characteristics of laser welding of Ti6Al4V and lead metal. J Mater Process Technol 212(7):1520–1527
Abdollah-Zadeh A, Saeid T, Sazgari B (2008) Microstructural and mechanical properties of friction stir welded aluminum/copper lap joints. J Alloys Compd 460(1–2):535–538
Yang J, Li Y, Zhang H, Guo W, Weckman D, Zhou N (2015) Dissimilar laser welding/brazing of 5754 aluminum alloy to DP 980 steel: mechanical properties and interfacial microstructure. Metall Mater Trans A 46(11):5149–5157
Hailat MM, Mian A, Chaudhury ZA, Newaz G, Patwa R, Herfurth HJ (2011) Laser micro-welding of aluminum and copper with and without tin foil alloy. Microsyst Technol 18(1):103–112
Zhao X, Tan C, **ao L, **a H, Chen B, Song X, Li L, Feng J (2018) Effect of the Ni coating thickness on laser welding-brazing of mg/steel. J Alloys Compd 769:1042–1058
Aonuma M, Nakata K (2009) Effect of alloying elements on interface microstructure of Mg–Al–Zn magnesium alloys and titanium joint by friction stir welding. Mater Sci Eng B 161(1–3):46–49
Costa A, Miranda RM, Quintino L (2006) Materials behavior in laser welding of hardmetals to steel. Mater Manuf Process 21(5):459–465
Mei SW, Gao M, Yan J, Zhang C, Li G, Zeng XY (2013) Interface properties and thermodynamic analysis of laser–arc hybrid welded Al/steel joint. Sci Technol Weld Join 18:293–300
Chen S, Zhai Z, Huang J, Zhao X, **ong J (2015) Interface microstructure and fracture behavior of single/dual-beam laser welded steel-Al dissimilar joint produced with copper interlayer. Int J Adv Manuf Technol 82(1–4):631–643
Kreimeyer M, Wagner F, Sepold G (2004) Development of a combined joining-forming process for aluminum-steel joints. International Congress on Applications of Lasers & Electro-Optics.
Windmann M, Röttger A, Kügler H, Theisen W (2017) Microstructure and mechanical properties of the heat-affected zone in laser-welded/brazed steel 22MnB5–AA6016 aluminum/AZ31 magnesium alloy. J Mater Process Technol 247:11–18
Lee K-J, Kumai S, Arai T, Aizawa T (2007) Interfacial microstructure and strength of steel/aluminum alloy lap joint fabricated by magnetic pressure seam welding. Mater Sci Eng A 471(1–2):95–101
Alexandre M, Simone M, Alexis D, Bruno M, Dominique G (2006) Temperature control in laser brazing of a steel/aluminium assembly using thermographic measurements. NDT E Int 39(1):272–276
Mohammadpour M, Yazdian N, Yang G, Wang H-P, Carlson B, Kovacevic R (2018) Effect of dual laser beam on dissimilar welding-brazing of aluminum to galvanized steel. Opt Laser Technol 98:214–228
Ussing T, Petersen LV, Nielsen CB, Helbo B, Højslet L (2007) Micro laser welding of polymer microstructures using low power laser diodes. Int J Adv Manuf Technol 33(1–2):198–205
Desai RS, Bag S (2014) Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding process. J Manuf Process 16(2):264–275
Rohde M, Markert C, Pfleging W (2010) Laser micro-welding of aluminum alloys: experimental studies and numerical modeling. Int J Adv Manuf Technol 50(1–4):207–215
Nakashiba S-I, Okamoto Y, Sakagawa T, Takai S, Okada A (2012) Micro-welding of copper plate by frequency doubled diode pumped pulsed Nd:YAG laser. Phys Procedia 39:577–584
Ventrella VA, Berretta JR, de Rossi W (2010) Pulsed Nd:YAG laser seam welding of AISI 316L stainless steel thin foils. J Mater Process Technol 210(14):1838–1843
Naeem M, Lewis S., Chinn J (2008) Microwelding performance comparison between a low power (125W) pulsed Nd: YAG laser and a low power (100-200W) single mode fiber laser. Pacific International Conference on Applications of Lasers and Optics. p 721–726
Mathieu A, Pontevicci S, Viala J-c, Cicala E, Matteï S, Grevey D (2006) Laser brazing of a steel/aluminium assembly with hot filler wire (88% Al, 12% Si). Mater Sci Eng A 435-436:19–28
Peyre P, Sierra G, Deschaux-Beaume F, Stuart D, Fras G (2007) Generation of aluminium–steel joints with laser-induced reactive wetting. Mater Sci Eng A 444(1–2):327–338
Rattana B, Taisei Y, Yukio M, Yoshiharu M (2007) Suppression of intermetallic reaction layer formation by controlling heat flow in dissimilar joining of steel and aluminum alloy. Mater Sci Eng A 467(1):108–113
Dharmendra C, Rao KP, Wilden J, Reich S (2011) Study on laser welding–brazing of zinc coated steel to aluminum alloy with a zinc based filler. Mater Sci Eng A 528(3):1497–1503
Shigeaki K, Takao Y (2002) Control of intermetallic compound layers at interface between steel and aluminum by diffusion-treatment. Mater Sci Eng A 338:44–53
Windmann M, Röttger A, Theisen W (2013) Phase formation at the interface between a boron alloyed steel substrate and an Al-rich coating. Surf Coat Technol 226:130–139
Cheng W-J, Wang C-J (2011) Effect of silicon on the formation of intermetallic phases in aluminide coating on mild steel. Intermetallics 19(10):1455–1460
Triantafyllidis D, Schmidt MJJ, Li L (2003) Comparison of high power diode laser and Nd:YAG laser microwelding of k-type thermocouples. J Mater Process Technol 138(1–3):102–108
Tran XV, Pan J (2010) Fatigue behavior of dissimilar spot friction welds in lap-shear and cross-tension specimens of aluminum and steel sheets. Int J Fatigue 32:1167–1179
Kah P, Vimalraj C, Martikainen J, Suoranta R (2015) Factors influencing Al-cu weld properties by intermetallic compound formation. Int J Mech Mater Eng 10(1):10
Brüggemann G, Mahrle A, Benziger T (2000) Comparison of experimental determined and numerical simulated mperature fields for quality assurance at laser beam welding of steels and aluminium alloyings. NDT E Int 33:453–463
Muhammad S, Han S-W, Na S-J, Gumenyuk A, Rethmeier M (2018) Study on the role of recondensation flux in high power laser welding by computational fluid dynamics simulations. J Laser Appl 30(1):012013
Pang S, Hirano K, Fabbro R, Jiang T (2015) Explanation of penetration depth variation during laser welding under variable ambient pressure. J Laser Appl 27(2):022007
Movahedi M, Kokabi AH, Seyed Reihani SM, Cheng WJ, Wang CJ (2013) Effect of annealing treatment on joint strength of aluminum/steel friction stir lap weld. Mater Des 44:487–492
Katayama S (2004) Laser welding of aluminium alloys and dissimilar metals. Weld Int 18(8):618–625
Sierra G, Peyre P, Deschaux-Beaume F, Stuart D, Fras G (2007) Steel to aluminium key-hole laser welding. Mater Sci Eng A 447(1–2):197–208
Cheng X, Huang X, Wang X, Sun D (2010) Influence of calcination on the adsorptive removal of phosphate by Zn-Al layered double hydroxides from excess sludge liquor. J Hazard Mater 177(1–3):516–523
Brüggemann G, Mahrle A, Benziger T (2000) Comparison of experimental determined and numerical simulated temperature field for quality assurance at laser beam welding of steels and aluminium alloyings. NDT E Int 33(7):453–463
Adisa S, Loginova I, Khalil A, Solonin A (2018) Effect of laser welding process parameters and filler metals on the weldability and the mechanical properties of AA7020 aluminium alloy. J Manuf Mater Process 2(2):33
Laukant H, Wallmann C, Müller M, Korte M, Stirn B, Haldenwanger HG, Glatzel U (2005) Fluxless laser beam joining of aluminium with zinc coated steel. Sci Technol Weld Join 10(2):219–226
Akhter R, Steen WM, Cruciani D (1988) Proc. 5th Int. Conf. Lasers in Manufacturing, 195–206 September 1988,© IFS Ltd and authors, ISBN 1–85423–021-2, Lasers Manuf. Proc. 5th Int. Conf. 13–14 Sept. 1988. p 195
Kattner UR, Burton BP (1993) Al-Fe (Aluminum-Iron), Phase Diagrams of Binary Iron Alloys. ASM International:12–28
Schubert E (1997) Konferenzband LASER '97 Munich. p 212
Borrisutthekul R, Yachi T, Miyashita Y, Mutoh Y (2007) Suppression of intermetallic reaction layer formation by controlling heat flow in dissimilar joining of steel and aluminum alloy. Mater Sci Eng A 467(1–2):108–113
Lahdo R, Springer A, Pfeifer R, Kaierle S, Overmeyer L (2016) High-power laser welding of thick steel-aluminum dissimilar joints. Phys Procedia 83:396–405
Seffer O, Springer A, Kaierle S (2018) Investigations on remote laser beam welding of dissimilar joints of austenitic chromium-nickel steel (X5CrNi18-10) and aluminum alloy (AA6082-T6) for battery housings. J Laser Appl 30(3):032404
Ion JC (2013) Laser beam welding of wrought aluminium alloys. Sci Technol Weld Join 5(5):265–276
Qiu R, Satonaka S, Iwamoto C (2009) Effect of interfacial reaction layer continuity on the tensile strength of resistance spot welded joints between aluminum alloy and steels. Mater Des 30(9):3686–3689
Kato T, Nunome K, Kaneko K, Saka H (2000) Formation of the ζ phase at an interface between an Fe substrate and a molten 0.2 mass% Al-Zn during galvannealing. Acta Mater 48(9):2257–2262
Marder AR (2000) Prog Mater Sci 191:191
Springer H, Kostka A, Payton EJ, Raabe D, Kaysser-Pyzalla A, Eggeler G (2011) On the formation and growth of intermetallic phases during interdiffusion between low-carbon steel and aluminum alloys. Acta Mater 59(4):1586–1600
Gupta IH (2003) Recycling - way to bankruptcy, Gummi, Fasern. Kunststoffe 56(5):269
Tsu**o J, Hidai K, Hasegawa A, Kanai R, Matsuura H, Matsushima K, Ueoka T (2002) Ultrasonic butt welding of aluminum, aluminum alloy and stainless steel plate specimens. Ultrasonics 40(1–8):371–374
**a H, Tan C, Li L, Ma N (2018) In situ SEM observations of fracture behavior of laser welded–brazed Al/steel dissimilar joint. J Mater Eng Perform 27(3):1047–1057
Guan Q, Long J, Yu P, Jiang S, Huang W, Zhou J (2019) Effect of steel to aluminum laser welding parameters on mechanical properties of weld beads. Opt Laser Technol 111:387–394
Huang J, Wang Z, Yang F, Yu S, Shi Y, Fan D (2018) Effects of powder on microstructure, tensile, and corrosion behavior of aluminum-steel joints. J Laser Appl 30(3):032006
Yang J, Chen J, Zhao W, Zhang P, Yu Z, Li Y, Zeng Z, Zhou N (2018) Diode laser welding/brazing of aluminum alloy to steel using a nickel coating. Appl Sci 8(6):922
Funding
This work is financially supported by the Natural Science Foundation of Guangdong Province (No. 2019A1515011844), and the Opening Project of Science and Technology on Reliability Physics and Application Technology of Electronic Component Laboratory (ZHD201801 and 31512050201).
Author information
Authors and Affiliations
Contributions
conceptualization, **tao Wang; investigation, Zheng Zhang; data curation, Luobin Zhang.; writing—original draft preparation, **tao Wang; writing—review and editing, Si Chen; visualization, **tao Wang; supervision, Jiahao Liu.; project administration, **ng Fu.
Corresponding authors
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Ethical approval
Not applicable.
Consent to participate
We confirm that the manuscript has been read and approved by all named authors.
Consent to publish
The authors agree to publication in the The International Journal of Advanced Manufacturing Technology.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Wang, J., Fu, X., Zhang, L. et al. A short review on laser welding/brazing of aluminum alloy to steel. Int J Adv Manuf Technol 112, 2399–2411 (2021). https://doi.org/10.1007/s00170-021-06607-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-06607-4