Development analysis and mitigates during aluminium alloy to galvanized steel dissimilar joining

Abstract The dissimilar joining of aluminum alloy and steel through arc welding presents significant challenges due to the differing physical, chemical, and thermal properties of these materials. Aluminum, with its lightweight and corrosion-resistant characteristics, and steel, known for its strength and durability, are increasingly used together in industries like automotive and aerospace. However, the process of welding these two materials introduces various issues, such as the formation of brittle intermetallic compounds (IMCs), zinc vaporization in galvanized steel, hot and cold cracking, residual stresses, and difficulties in heat input control. These challenges compromise the mechanical properties and integrity of the welded joint, affecting its performance in real-world applications. This review paper examines the primary issues faced during aluminum-to-steel dissimilar welding by arc welding techniques, including Gas Metal Arc Welding (GMAW), Metal Inert Gas (MIG) welding, and other variants. Additionally, it explores the solutions and mitigation strategies proposed in recent studies, such as welding parameter optimization, the use of interlayers, shielding gas modifications, and advanced welding techniques like Cold Metal Transfer (CMT) and Friction Stir Welding (FSW). The paper provides a comprehensive overview of the current state of knowledge on this topic and outlines potential avenues for future research to improve the quality and reliability of aluminum-steel joints for various industrial applications.