Abstract
The purpose of this study was to predict the brazed-bead shape and the distribution of intermetallic compound (IMC) thickness at the interface of a dissimilar laser-brazed joint between aluminum alloy and high-strength steel. Laser brazing was carried out to experimentally clarify the relationship between brazing conditions, bead geometry, and IMC formation. A thermo-fluid analysis was used to simulate the laser brazing process. The experimental and analytical results of the bead geometry were compared and found to be generally in agreement. The temperature history at the dissimilar material interface between the brazed metal and the high-strength steel was obtained from the analysis, and the IMC thickness at the interface was predicted using the IMC growth rate equation for Al-Si flux-cored wire and high-strength steel. The prediction results largely agreed with the experimental results. Therefore, it was possible to predict the brazed-bead geometry in dissimilar laser brazing of aluminum alloy and high-strength steel, as well as the IMC thickness formed at the interface between the dissimilar materials.
