Achieving superior aluminum-steel dissimilar joining via ultrasonic spot welding: Microstructure and fracture behavior
Bibliographic record
Abstract
High-strength dissimilar welded joints of AA2024-T3 alloy with an AA1230 coating and galvanized high-strength low-alloy (HSLA) steel were attained through ultrasonic spot welding (USW) in this study. The tensile lap shear failure loads over a welding energy range between 2000 J and 3000 J were observed to meet or surpass the values specified in the AWS D17.2 standard. The highest average tensile lap shear strength was obtained to be ∼169 MPa due to the formation of a ∼30-70 μm thick Al-Zn diffusion layer without the presence of intermetallic compounds. The substrate failure from the softer AA1230 coating on the AA2024 side under tensile loading and cyclic loading at higher cyclic loads was observed, which reflected a robust sticking capability. The partial failure from AA1230 coating consisted of characteristic shear dimples, allowing high plasticity upon shear deformation. While the 1000 J welds failed mainly via substrate failure from AA1230 and transverse through-thickness (TTT) cracking in AA2024, the cohesive failure across the Al-Zn diffusion layer and adhesive failure from the Al-Fe-intermetallic/Al-Zn-diffusion layer interface were observed in the welds made at 3000 J, corresponding to the superior bonding strength and longer fatigue life.
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How this classification was reachedexpand
Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.001 | 0.001 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one teacher head, not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".