Analysis of laser welding on dissimilar materials with the influence of adding interlayer

The laser welding of dissimilar materials poses several challenges in practical applications, such as molten pool instability, the formation of intermetallic compounds (IMCs), and cracking caused by differential thermal stresses. In this study, we investigated the impact of incorporating a nickel (Ni) foil as an intermediate layer on lap joints of dissimilar materials (SS304 and Al6061) welded using the continuous laser welding (CLW) technique. The thermomechanical simulation accurately predicted the width and depth of SS304–Ni–Al6061 joints, with deviations of merely 3.92% and 19.04% from experimental results, respectively. Residual stress analysis revealed that the addition of a nickel foil reduced residual stress in the heat-affected zone (HAZ) and improved joint fatigue life. Furthermore, the incorporation of 0.1 and 0.2 mm Ni foils enhanced joint strength and effectively suppressed the formation of brittle intermetallic compounds, resulting in a remarkable maximum lap shear force of up to 1026 N. The simulation results for the shear load-displacement curve displayed excellent agreement with experimental data, with a deviation of only 6%. Notably, joints with the Ni foil demonstrated a greater ability to prevent crack formation caused by thermal expansion mismatch compared to joints without the Ni foil. The Ni interlayer served as a diffusion barrier and stress buffer, promoting a more uniform microstructure and reducing the likelihood of crack formation in bonded materials. Overall, this study comprehensively investigates the impact of incorporating a nickel interlayer on laser-welded lap joints of dissimilar materials. The findings offer valuable insights for practical applications, enabling improved joint strength, reliability, and crack resistance in laser welding dissimilar materials.