The Need

Welding or bonding steel to aluminum is challenging due to the formation of brittle Fe-Al intermetallic compounds, which weaken the joints. Current methods require alternative, costly joining processes. There is a critical need for a solution that allows the use of traditional welding techniques, such as resistance spot welding (RSW), to create strong, reliable joints between steel and aluminum.

The Technology

OSU researchers have created an innovative steel alloy that limits the formation of brittle Fe-Al intermetallics during welding. This alloy can be used as an interlayer, filler metal, or powder, enabling the use of traditional welding processes like RSW. Initial testing has shown promising results, indicating stronger joints and potential for widespread industrial application. The alloy is designed to optimize microstructure-processing-fatigue relations, ensuring durability under cyclic loading.

Commercial Applications

• Automotive industry
• Aerospace industry
• Construction/Manufacturing
• Marine industry
• Medical Implants and Devices

Benefits/Advantages

• Enables the use of traditional RSW, reducing the need for alternative joining processes.
• Creates stronger, more reliable joints by limiting brittle intermetallic formation.
• Cost-effective solution for industries requiring mixed-material welding.
• Potential for customization with specific alloy compositions to meet various industrial needs.
• Improved fatigue properties, ensuring long-term durability of joints under cyclic loading.