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Chenghao Wu, Haibin Liu, Ruishan Xie, Yangyang Sun, Jian Lin, Yanhua Zhao, Li Zhou, and Shujun Chen, Review on interface bonding mechanisms and cross-scale regulation of aluminum-steel dissimilar metals during solid-state friction-based welding/additive manufacturing, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-026-3415-8
Chenghao Wu, Haibin Liu, Ruishan Xie, Yangyang Sun, Jian Lin, Yanhua Zhao, Li Zhou, and Shujun Chen, Review on interface bonding mechanisms and cross-scale regulation of aluminum-steel dissimilar metals during solid-state friction-based welding/additive manufacturing, Int. J. Miner. Metall. Mater., (2026). https://doi.org/10.1007/s12613-026-3415-8
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铝/钢异种金属固相摩擦焊接/增材制造的界面结合机制及跨尺度调控综述

摘要: 铝/钢复合结构可充分发挥铝合金与钢的协同性能优势,已成为满足汽车制造、航空航天工程等领域轻量化需求的关键解决方案。但铝与钢之间热物理及化学性能的巨大差异,给传统熔焊工艺带来了固有难题,显著降低铝/钢异质构件的接头性能,制约其大规模工业化应用。固态摩擦焊接具备无液相生成、热输入低、可破碎界面氧化膜等核心优势,现已成为实现铝/钢异质界面可靠成形的重要技术手段。目前该领域已发展出三类成熟技术:传统摩擦焊接、搅拌摩擦焊接以及搅拌摩擦增材制造。上述技术均依靠“低热输入-剧烈塑性变形”作用机制,获得良好的界面结合质量。尽管相关研究已取得一定进展,但现有技术仍存在若干瓶颈:厚截面构件连接能力不足、金属间化合物层的调控精度有限、极端环境工况下的研究较为匮乏,上述问题限制了该技术的进一步突破。为此,本文从技术方法与机理研究方面,系统梳理铝/钢固态摩擦焊的主流工艺类型、工艺特征及适用场景;深入剖析界面机械结合与冶金结合的核心作用机制,并对界面跨尺度调控策略展开探讨。本综述旨在为铝/钢固态焊接技术的后续工艺优化、界面结合机理的深度解析以及工程化应用方向提供参考。

 

Review on interface bonding mechanisms and cross-scale regulation of aluminum-steel dissimilar metals during solid-state friction-based welding/additive manufacturing

Abstract: Aluminum/steel hybrid structures, leveraging the synergistic advantages of aluminum alloys and steel, have emerged as a critical solution to lightweighting demands in industries such as automotive manufacturing and aerospace engineering. However, the significant differences in thermophysical and chemical properties between aluminum and steel pose inherent challenges for conventional fusion welding, which seriously restricts the joint quality and large-scale industrial application of aluminum/steel components. Solid-state friction welding, characterized by core advantages including no liquid phase formation, low heat input, and the ability to break up interfacial oxide films, effectively circumvents the inherent limitations of fusion welding, thus establishing itself as a pivotal technical route for aluminum/steel dissimilar interface formation. To date, three mature technological variants have been developed—traditional friction welding, friction stir welding, and friction stir additive manufacturing—which achieve a balance between interfacial bonding quality through the “low heat input and severe plastic deformation” mechanism. However, current research still faces some problems, such as the limited capability for joining thick-section components, insufficient precision in intermetallic compound layers regulation, and inadequate investigations into adaptability under extreme environments. These limitations hinder further technological breakthroughs. Thus, this review systematically summarizes the mainstream technical types, process characteristics, and application scenarios of aluminum/steel solid-state friction welding from the perspectives of technical methodology and mechanism exploration. Simultaneously, it conducts an in-depth analysis of the core mechanisms underlying interfacial mechanical bonding and metallurgical bonding, and further explores cross-scale regulation strategies. This work aims to provide research insights for the subsequent optimization of aluminum/steel solid-state welding technologies, the deepening of bonding mechanism understanding, and the direction of industrial application.

 

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