Direct aluminium–stainless steel joints are difficult to create by the vaporized foil actuator welding (VFAW) method because brittle intermetallic compounds (IMCs) tend to form along the interface. The use of an interlayer as a transition layer between the two materials with vast difference in hardness and ductility was proposed as a solution to reduce the formation of the IMCs. In this work, VFAW was used to successfully weld sheet aluminium alloy 5A06 to stainless steel 321 with a 3003 aluminium alloy interlayer. Input energy levels of 6 kJ, 8 kJ, 10 kJ, and 12 kJ were used and as a trend, higher energy inputs resulted in higher impact velocities, larger weld area, and better mechanical properties. In lap-shear and peel testing, all samples failed at the interface of the interlayer and target. At 10 kJ energy input, flyer velocities up to 935 m/s, lap-shear peak load of 44 kN, and peel load of 2.15 kN were achieved. Microstructure characterization and element distribution were performed, and the results show a wavy pattern created between the flyer and interlayer which have similar properties, and the interface between the interlayer and target was dominated by element diffusion and IMCs identified mainly as FeAl₃ and FeAl. The results demonstrate VFAW is a suitable joining method for dissimilar metals such as aluminium alloy and stainless steel, which has a broad and significant application prospect in aerospace and chemical industry.

In order to improve the comprehensive mechanical properties of the welded joints of the 5A06 aluminum alloy, friction stir welded (FSW) joints were subjected to deep cryogenic treatment (DCT). The microstructure and mechanical properties were characterised using metallographic microscopy, x-ray diffractometer (XRD), energy spectrometer, microhardness tests, and tensile tests. The experimental results show that DCT refines the structure significantly due to the large temperature difference. This refinement results from an increase in Mg atoms within the α-Al solid solution through the precipitation of Al atoms, forming the Al₃Mg₂ phase. This enhancement in plasticity is achieved through dispersion distribution. Moreover, as the treatment time of DCT increases, the mechanical properties of the welded joint also improve significantly. The microhardness of the welding joint peaked at DCT3h, rising from 78.8 HV at DCT0h to 87.2 HV at DCT3h. Meanwhile, the tensile strength of the joint reached its maximum at DCT12h, rising from 358.7 MPa at DC0h to 385.3 MPa at DCT12h, representing a 7.4% increase. These experimental results underscore the significant impact of DCT on improving the welded joints.

Conventional welding methods encounter significant challenges, including poor weldability, low joint strength, and the formation of brittle intermetallic compounds, primarily due to the substantial disparities in the physical and chemical properties of aluminum and iron. To mitigate these issues, the vaporizing foil actuator welding (VFAW) process has emerged as a highly promising solid-phase welding technology, particularly suitable for joining dissimilar metals with pronounced differences in properties, such as aluminum alloys and stainless steels. The present study provides an innovative quantitative analysis of the interfacial impact energy conversion mechanisms within the VFAW process. The analysis reveals that the energy responsible for accelerating the flyer workpiece comprises burst vaporization energy (\(E_d\)) and continuous vaporization energy (\(E_p\)), with \(E_d\) identified as the primary energy source, contributing approximately 65–80% of the total energy required for acceleration. Further examination elucidates the mechanisms underlying heat generation and transfer during the interface collision. The investigation identifies the formation of an overheating zone at the interface, attributed to the combined effects of plastic deformation energy and adiabatic shear energy within the flyer workpiece. Consequently, the interface temperature can rise significantly, reaching up to 1394 K, with impact velocities as high as 925 m/s. The analyses contribute to establishing a theoretical foundation for understanding the interface bonding mechanisms characteristic of the vaporizing foil actuator welding method.

The composite structure of aluminium alloy and stainless steel provides a wide range of comprehensive advantages, encompassing properties such as lightweight, high strength, and corrosion resistance. These advantages make composite structure particularly suitable for various applications in industries such as transportation and chemicals. One innovative solid-phase welding technology that is well suited for joining dissimilar materials is vaporizing foil actuator welding. This technology allows for the welding of composite structures made of aluminium and stainless steel, despite the significant differences in physical and chemical properties. To enhance the vaporizing welding process, this paper proposes the introduction of an interlayer between the dissimilar materials. The interlayer consists of a third material that is added to bridge the gap between materials with differing hardness and plasticity. The main objective of introducing the interlayer is to minimise performance disparities and reduce the formation of intermetallic compounds at the interface. By examining the vaporizing foil actuator welding process of aluminium alloy and stainless steel with the interlayer, it aims to analyse the characteristics of the interface morphology. Additionally, this study investigates the energy conversion mechanism of the aluminium foil gasification process and explore the influence of the interlayer on the microstructure and mechanical properties of the interface between aluminium alloy and stainless-steel joints.

In this study, the application of magnetic pulse welding was employed for the production of tubular joints using 1060 aluminium and 321 stainless steel. Two crucial process parameters, the charging voltage, and the gap between the outer and inner tubes, were subjected to mechanical property tests and morphology analysis. The joints that exhibited favourable mechanical properties were obtained with a gap size of 1.25 mm and a charging voltage exceeding 3.5 kV. The presence of intermetallic compounds at the joint interface indicates the occurrence of fusion in the transition zone. The quantity of molten metal increased with an increase in the charging voltage. The aluminium content in the intermetallic compounds within the transition zone decreased as one moved from the 1060 aluminium side towards the 321 stainless steel side. The gap distance plays an important role in determining the efficiency of energy transformation at the joint interface during magnetic pulse welding (MPW). A smaller gap distance resulted in a substantial amount of energy being transformed into plastic deformation in the transition zone. Conversely, a greater gap distance led to a significant amount of energy from the electrical charging voltage being converted into thermal energy. The MPW joint consisted of bonding, mechanical interlock, and non-bonding regions. The mechanical properties of the joint were influenced by the composition of the intermetallic compound. Taking into account the impact of morphologies and elastic modulus of the transition zone, an increase in the melting of stainless steel during the welding process was found to be advantageous for the MPW of 1060 aluminium to 321 stainless steel.