Browse Publications Technical Papers 1999-01-0660

Joining Aluminum to Steel with Transition Material 1999-01-0660

1006 steel clad aluminum has been used as a transition material to directly spot weld steel to aluminum. Advantages of the clad metal transition include the ability to spot weld with existing equipment and reduction of dissimilar metal crevice corrosion at the steel-aluminum interface. Sheet steel between 0.8mm and 2.0mm has been spot welded to aluminum between 0.8mm and 3.0mm in a variety of combinations with the transition material.
This paper contains specific spot welding parameters for a variety of joints containing steel and aluminum at thicknesses normally encountered in body applications. The mechanism of weld nugget formation for aluminum-transition-steel joints is evaluated. Weld lobes established according to SAE and Aluminum Association guidelines are presented. The effect of electrode design on joint strength and heat balance are discussed.
A portion of the paper deals with the use of transition material clips for reducing galvanic corrosion when joining aluminum sheet to steel. Results of accelerated laboratory, marine atmospheric exposure and field test plate studies are reviewed. Quantitative data on crevice corrosion rates for various joints are included.


Subscribers can view annotate, and download all of SAE's content. Learn More »


Members save up to 18% off list price.
Login to see discount.
Special Offer: Download multiple Technical Papers each year? TechSelect is a cost-effective subscription option to select and download 12-100 full-text Technical Papers per year. Find more information here.

Due to current capacity constraints, printed versions of our publications - including standards, technical papers, EDGE Reports, scholarly journal articles, books, and paint chips - may experience shipping delays of up to four to six weeks. We apologize for any inconvenience.
We also recommend:

Joining Dissimilar Metals With Transition Materials


View Details


A New High Strength CAB Evaporator Plate Alloy with High Corrosion Resistance


View Details


Ultrasonic Spot Welding of Galvanized Mild Steel to Magnesium AZ31B


View Details