In Situ SEM Observations of Fracture Behavior of Laser Welded–Brazed Al/Steel Dissimilar Joint

Laser welding–brazing of 6061-T6 aluminum alloy to DP590 dual-phase steel with Al-Si12 flux-cored filler wire was performed. The microstructure at the brazing interface was characterized. Fracture behavior was observed and analyzed by in situ scanning electron microscope. The microstructure of the brazing interface showed that inhomogeneous intermetallic compounds formed along the thickness direction, which had a great influence on the crack initiation and propagation. In the top region, the reaction layer at the interface consisted of scattered needle-like Fe(Al,Si)₃ and serration-shaped Fe_1.8Al_7.2Si. In the middle region, the compound at the interface was only serration-shaped Fe_1.8Al_7.2Si. In the bottom region, the interface was composed of lamellar-shaped Fe_1.8Al_7.2Si. The cracks were first detected in the bottom region and propagated from bottom to top along the interface. At the bottom region, the crack initiated and propagated along the Fe_1.8Al_7.2Si/weld seam interface during the in situ tensile test. When the crack propagated into the middle region, a deflection of crack propagation appeared. The crack first propagated along the steel/Fe_1.8Al_7.2Si interface and then moved along the weld seam until the failure of the joint. The tensile strength of the joint was 146.5 MPa. Some micro-cracks were detected at Fe(Al,Si)₃ and the interface between the steel substrate and Fe(Al,Si)₃ in the top region while the interface was still connected.