The effect of FeCoCrCuAl0.2 high-entropy alloy interlayer on dissimilar resistance spot welding of AISI304 to AISI420 stainless steels

Document Type : Research Paper

Authors

School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran

10.22059/jufgnsm.2025.02.12

Abstract

The widespread use of stainless steels in various industries due to their appropriate strength and corrosion resistance necessitates the investigation of dissimilar joints between them. However, resistance spot welding (RSW) of AISI304 austenitic stainless steel (ASS304) to AISI420 martensitic stainless steel (MSS420), particularly in case of employing interlayer, has not been examined so far. Due to appreciable difference in their physical properties and metallurgical consistency as main concerns, the effect of FeCoNiCuAl0.2 high-entropy alloy (HEA) interlayer on the microstructural and mechanical behavior of the joints was investigated. It was found that copper exhibited a segregation in the HEA cast ingot because of its positive mixing enthalpy with other elements. This issue was responsible for the formation of hot cracking in the weld nugget, resulting in a decrease in mechanical strength of the joints. The effect of welding current on the joint strength was investigated as well. The relatively suitable current intensity in this joint was found to be 7 kA, and the maximum failure force was achieved in this case at about 6000 N. At lower current intensity (6 kA) due to insufficient heat input, proper fusion between the base metals and the interlayer was not formed and the maximum fracture force was about 4000 N. At 8 kA current intensity, due to higher heat input and increased weld nugget size, a higher fracture force was obtained than at 6 kA current intensity, but the displacement was reduced. The decrease in fracture toughness at 8 kA current intensity was attributed to spattering and increased copper segregation due to higher temperature (more diffusion of copper atoms).

Keywords

References

  1. A. Malekan, M. Malekan, N. Banimostafa Arab, and H. Bayat Tork, "Microstructure and mechanical properties in dissimilar friction stir welding of 316 stainless steel to 4140 steel," Journal of Ultrafine Grained and Nanostructured Materials, vol. 56, no. 2, pp. 147-156, 2023.
  2. S. Mohammadzehi and H. Mirzadeh, "Grain refinement of austenitic stainless steels by cross rolling and annealing treatment: A review," Journal of Ultrafine Grained and Nanostructured Materials, vol. 57, no. 2, pp. 112-119, 2024.
  3. R. Kacar and O. Baylan, "An investigation of microstructure/property relationships in dissimilar welds between martensitic and austenitic stainless steels," Materials & Design, vol. 25, no. 4, pp. 317-329, 2004.
  4. Z. Sun and H.-Y. Han, "Weldability and properties of martensitic/austenitic stainless steel joints," Materials science and technology, vol. 10, no. 9, pp. 823-829, 1994.
  5. S. S. Sashank, S. Rajakumar, and R. Karthikeyan, "Dissimilar welding of austenitic and martensitic stainless steel joints for nuclear applications: a review," in E3S Web of Conferences, 2021, vol. 309: EDP Sciences, p. 01187.
  6. T. Das, R. Das, and J. Paul, "Resistance spot welding of dissimilar AISI-1008 steel/Al-1100 alloy lap joints with a graphene interlayer," Journal of Manufacturing Processes, vol. 53, pp. 260-274, 2020.
  7. H. Li, D. Sun, X. Cai, P. Dong, and W. Wang, "Laser welding of TiNi shape memory alloy and stainless steel using Ni interlayer," Materials & Design, vol. 39, pp. 285-293, 2012.
  8. B. Cantor, I. T. Chang, P. Knight, and A. Vincent, "Microstructural development in equiatomic multicomponent alloys," Materials Science and Engineering: A, vol. 375, pp. 213-218, 2004.
  9. J. W. Yeh et al., "Nanostructured high‐entropy alloys with multiple principal elements: novel alloy design concepts and outcomes," Advanced engineering materials, vol. 6, no. 5, pp. 299-303, 2004.
  10. D. B. Miracle and O. N. Senkov, "A critical review of high entropy alloys and related concepts," Acta Materialia, vol. 122, pp. 448-511, 2017.
  11. B. Choi et al., "Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment," Journal of Materials Research and Technology, 2025.
  12. S. Daryoush, H. Mirzadeh, and A. Ataie, "Nanostructured high-entropy alloys by mechanical alloying: A review of principles and magnetic properties," Journal of Ultrafine Grained and Nanostructured Materials, vol. 54, no. 1, pp. 112-120, 2021.
  13. Z. Kang, Y. Wenxiao, R. Baokai, W. Gang, and Y. Ping, "Microstructure and mechanical properties of resistance spot welded dissimilar aluminum/steel joints fabricated using high entropy alloy as interlayer," Materials Characterization, vol. 216, p. 114278, 2024.
  14. H. Wang, J. Xie, Y. Chen, W. Liu, and W. Zhong, "Effect of CoCrFeNiMn high entropy alloy interlayer on microstructure and mechanical properties of laser-welded NiTi/304 SS joint," Journal of materials research and technology, vol. 18, pp. 1028-1037, 2022.
  15. H. Azhari-Saray, M. Sarkari-Khorrami, A. Nademi-Babahadi, and S. F. Kashani-Bozorg, "Dissimilar resistance spot welding of 6061-T6 aluminum alloy/St-12 carbon steel using a high entropy alloy interlayer," Intermetallics, vol. 124, p. 106876, 2020.
  16. S. Manoochehri and M. S. Khorrami, "Friction stir welding of AA5010 aluminum alloy to St-12 carbon steel using CoCrCuFeNi high entropy alloy interlayer," Journal of Manufacturing Processes, vol. 99, pp. 298-309, 2023.
  17. J. C. Lippold and D. J. Kotecki, Welding metallurgy and weldability of stainless steels. 2005.
  18. H. Zhou, X. Gu, X. Gu, J. Dong, and G. Xu, "Improvement in microstructure and mechanical properties of laser welded steel/aluminum alloy lap joints using high-entropy alloy interlayer," Journal of Materials Research and Technology, vol. 20, pp. 139-146, 2022.
  19. Y. Du et al., "Microstructure and mechanical properties of Ti2AlNb diffusion bonding using multi-phase refractory high-entropy alloy interlayer," Materials Science and Engineering: A, vol. 836, p. 142688, 2022.
  20. A. Takeuchi and A. Inoue, "Classification of bulk metallic glasses by atomic size difference, heat of mixing and period of constituent elements and its application to characterization of the main alloying element," Materials transactions, vol. 46, no. 12, pp. 2817-2829, 2005.
  21. C. Zhang, F. Zhang, S. Chen, and W. Cao, "Computational thermodynamics aided high-entropy alloy design," Jom, vol. 64, no. 7, pp. 839-845, 2012.
  22. A. Mirshekari, G. R. Khayati, and S. Arjmand, "TIG-clad Fe-based AlCoCrNiTi0. 5 high-entropy alloy coating on low-carbon steel: microstructure, microhardness, and corrosion resistance," Surface and Coatings Technology, p. 132826, 2025.
  23. W.-R. Wang, W.-L. Wang, S.-C. Wang, Y.-C. Tsai, C.-H. Lai, and J.-W. Yeh, "Effects of Al addition on the microstructure and mechanical property of AlxCoCrFeNi high-entropy alloys," Intermetallics, vol. 26, pp. 44-51, 2012.
  24. C. Qian, H. Ghassemi-Armaki, L. Shi, J. Kang, A. S. Haselhuhn, and B. E. Carlson, "Competing fracture modes in Al-steel resistance spot welded structures: Experimental evaluation and numerical prediction," International Journal of Impact Engineering, vol. 185, p. 104838, 2024. 
Journal of Ultrafine Grained and Nanostructured Materials
Volume 58, Issue 2
December 2025
Pages 277-286

Files

History

  • Receive Date: 30 August 2025
  • Revise Date: 08 November 2025
  • Accept Date: 08 November 2025

Share

How to cite

Statistics