{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,5,4]],"date-time":"2026-05-04T23:52:25Z","timestamp":1777938745930,"version":"3.51.4"},"reference-count":31,"publisher":"SAGE Publications","license":[{"start":{"date-parts":[[2026,2,4]],"date-time":"2026-02-04T00:00:00Z","timestamp":1770163200000},"content-version":"tdm","delay-in-days":0,"URL":"https:\/\/journals.sagepub.com\/page\/policies\/text-and-data-mining-license"}],"content-domain":{"domain":["journals.sagepub.com"],"crossmark-restriction":true},"short-container-title":["Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications"],"abstract":"<jats:p>Dissimilar joining of aluminum (Al) and steel (St) is essential for lightweighting in automotive and aerospace industries. However, their distinct physical and thermal properties present considerable welding challenges. This study investigates the microstructure and fracture behavior of TIG weld-brazed AA5083 aluminum to hot-dip galvanized St37 steel T-joints, using ER4043 and ER5356 filler metals. Optical and scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) characterized the intermetallic compound (IMC) layers at the Al-St interface.<\/jats:p>\n                  <jats:p>Results show that silicon (Si) in the ER4043 filler reduced the IMC layer thickness to 2\u2005\u00b5m and modified its structure, leading to a more desirable interface compared to the ER5356 filler, which produced IMC layers up to 16\u2005\u00b5m. Although zinc coating on the steel improved initial wettability, high welding temperatures led to substantial zinc evaporation and subsequent porosity within the weld metal, impairing joint quality. Tensile tests indicated that both weld-brazed joints fractured predominantly in a brittle manner. Despite thicker IMC layers in some regions, the ER5356 joint achieved a slightly higher peak load (1342 N) than the ER4043 joint (1263 N), indicating intricate relationships between IMC morphology, porosity, and filler metal composition that influenced joint strength. These results suggest that a higher preheating temperature (300\u2013400\u00b0C) could mitigate zinc evaporation and enhance overall joint performance.<\/jats:p>","DOI":"10.1177\/14644207261418507","type":"journal-article","created":{"date-parts":[[2026,2,4]],"date-time":"2026-02-04T18:08:06Z","timestamp":1770228486000},"update-policy":"https:\/\/doi.org\/10.1177\/sage-journals-update-policy","source":"Crossref","is-referenced-by-count":0,"title":["Microstructure and fracture analysis of TIG weld-brazed aluminum-steel T-joints"],"prefix":"10.1177","author":[{"ORCID":"https:\/\/orcid.org\/0009-0005-6181-9938","authenticated-orcid":false,"given":"Masih","family":"Bolhasani Hesari","sequence":"first","affiliation":[{"name":"Arak University"}]},{"given":"Mohammad Hosein","family":"Feizollah","sequence":"additional","affiliation":[{"name":"Arak University"}]},{"given":"Reza","family":"Beygi","sequence":"additional","affiliation":[{"name":"Arak University"}]},{"given":"Fardin","family":"Nematzadeh","sequence":"additional","affiliation":[{"name":"Materials and Energy Research Center"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3234-8795","authenticated-orcid":false,"given":"Ali","family":"Khalfallah","sequence":"additional","affiliation":[{"name":"University of Coimbra"}]},{"given":"Elango","family":"Natarajan","sequence":"additional","affiliation":[{"name":"UCSI University"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2750-8184","authenticated-orcid":false,"given":"Eduardo AS","family":"Marques","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Faculty of Engineering of the University of Porto, Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3272-4591","authenticated-orcid":false,"given":"Lucas FM","family":"da Silva","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Faculty of Engineering of the University of Porto, Porto, Portugal"}]}],"member":"179","published-online":{"date-parts":[[2026,2,4]]},"reference":[{"key":"e_1_3_2_2_2","doi-asserted-by":"publisher","DOI":"10.1016\/0261-3069(86)90098-1"},{"key":"e_1_3_2_3_2","doi-asserted-by":"publisher","DOI":"10.1016\/B978-0-08-100270-4.00013-5"},{"key":"e_1_3_2_4_2","volume-title":"Light alloys: metallurgy of the light metals","author":"Polmear I","year":"2017","unstructured":"Polmear I, et al. Light alloys: metallurgy of the light metals. Oxford, United Kingdom: Butterworth-Heinemann, 2017."},{"key":"e_1_3_2_5_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jallcom.2018.03.224"},{"key":"e_1_3_2_6_2","doi-asserted-by":"publisher","DOI":"10.1007\/s10853-006-0644-0"},{"key":"e_1_3_2_7_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jmatprotec.2017.07.003"},{"key":"e_1_3_2_8_2","volume-title":"Binary alloy phase diagrams","author":"Okamoto H","year":"1990","unstructured":"Okamoto H, Massalski T. Binary alloy phase diagrams, vol. 12. Materials Park, OH, USA: ASM International, 1990."},{"key":"e_1_3_2_9_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.mtcomm.2015.09.004"},{"key":"e_1_3_2_10_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.scriptamat.2016.02.004"},{"key":"e_1_3_2_11_2","first-page":"1321","article-title":"Joining sheets made from dissimilar materials by hole hemming","volume":"236","author":"Kasaei MM","unstructured":"Kasaei MM, da Silva LFM. Joining sheets made from dissimilar materials by hole hemming. Proc Inst Mech Eng Part L: J Mater: Des Appl Jun. 2022; 236: 1321\u20131332.","journal-title":"Proc Inst Mech Eng Part L: J Mater: Des Appl"},{"key":"e_1_3_2_12_2","first-page":"1353","article-title":"Evaluations of nanomechanical and indentation creep of diffusion-bonded aluminum and austenitic stainless steel joint interface","volume":"239","author":"Khan S","unstructured":"Khan S, Khadija, Junaid M, et al. Evaluations of nanomechanical and indentation creep of diffusion-bonded aluminum and austenitic stainless steel joint interface. Proc Inst Mech Eng Part L: J Mater: Des Appl Jul. 2025; 239: 1353\u20131365.","journal-title":"Proc Inst Mech Eng Part L: J Mater: Des Appl"},{"key":"e_1_3_2_13_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.matdes.2009.12.005"},{"key":"e_1_3_2_14_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jallcom.2009.08.084"},{"key":"e_1_3_2_15_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.matdes.2015.10.144"},{"key":"e_1_3_2_16_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jmatprotec.2013.11.022"},{"key":"e_1_3_2_17_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jmatprotec.2013.08.005"},{"key":"e_1_3_2_18_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.msea.2011.11.090"},{"key":"e_1_3_2_19_2","first-page":"2506","article-title":"Mechanical and microstructural characterization of cold metal transfer (CMT) spot aluminium-steel weld-brazed joints","volume":"236","author":"Singh J","unstructured":"Singh J, Arora KS, Shukla DK, et al. Mechanical and microstructural characterization of cold metal transfer (CMT) spot aluminium-steel weld-brazed joints. Proc Inst Mech Eng Part L: J Mater: Des Appl Dec. 2022; 236: 2506\u20132515.","journal-title":"Proc Inst Mech Eng Part L: J Mater: Des Appl"},{"key":"e_1_3_2_20_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.scriptamat.2009.06.022"},{"key":"e_1_3_2_21_2","volume-title":"Standard guide for preparation of metallographic Specimens, ASTM E3-11","author":"Testing, A.S.f. and Materials","year":"2017","unstructured":"Testing, A.S.f. and Materials. Standard guide for preparation of metallographic Specimens, ASTM E3-11. West Conshohocken, Pennsylvania, USA: American Society for Testing and Materials United States of America, 2017."},{"key":"e_1_3_2_22_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.msea.2015.08.036"},{"key":"e_1_3_2_23_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.matchar.2022.111811"},{"key":"e_1_3_2_24_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.mtcomm.2025.111833"},{"key":"e_1_3_2_25_2","first-page":"1027","article-title":"A novel lap-butt joint design for FSW of aluminum to steel in Tee-configuration: joining mechanism, intermetallic formation, and fracture behavior","volume":"13","author":"Beygi R","unstructured":"Beygi R, Talkhabi AA, Mehrizi MZ, et al. A novel lap-butt joint design for FSW of aluminum to steel in Tee-configuration: joining mechanism, intermetallic formation, and fracture behavior. Met May 2023; 13: 1027.","journal-title":"Met"},{"key":"e_1_3_2_26_2","volume-title":"ASTM E407-07 (2015) e1, Standard practice for microetching metals and alloys","author":"ASTM A","year":"1999","unstructured":"ASTM A. ASTM E407-07 (2015) e1, Standard practice for microetching metals and alloys. West Conshohocken: ASTM International, 1999."},{"key":"e_1_3_2_27_2","doi-asserted-by":"publisher","DOI":"10.3390\/met10020253"},{"key":"e_1_3_2_28_2","doi-asserted-by":"publisher","DOI":"10.1007\/s11771-021-4880-x"},{"key":"e_1_3_2_29_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.msea.2010.03.097"},{"key":"e_1_3_2_30_2","unstructured":"Effenberg G et al. Ternary alloy systems. Phase diagrams crystallographic and thermodynamic data critically evaluated by MSIT {sup registered}. Subvol. D. Iron systems. Pt. 4: Selected systems from Cu-Fe-Si to Fe-NU. 2008."},{"key":"e_1_3_2_31_2","doi-asserted-by":"publisher","DOI":"10.1016\/S0308-0161(01)00074-6"},{"key":"e_1_3_2_32_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.matdes.2013.08.011"}],"container-title":["Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/journals.sagepub.com\/doi\/pdf\/10.1177\/14644207261418507","content-type":"application\/pdf","content-version":"vor","intended-application":"text-mining"},{"URL":"https:\/\/journals.sagepub.com\/doi\/full-xml\/10.1177\/14644207261418507","content-type":"application\/xml","content-version":"vor","intended-application":"text-mining"},{"URL":"https:\/\/journals.sagepub.com\/doi\/pdf\/10.1177\/14644207261418507","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2026,5,2]],"date-time":"2026-05-02T04:49:56Z","timestamp":1777697396000},"score":1,"resource":{"primary":{"URL":"https:\/\/journals.sagepub.com\/doi\/10.1177\/14644207261418507"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2026,2,4]]},"references-count":31,"alternative-id":["10.1177\/14644207261418507"],"URL":"https:\/\/doi.org\/10.1177\/14644207261418507","relation":{},"ISSN":["1464-4207","2041-3076"],"issn-type":[{"value":"1464-4207","type":"print"},{"value":"2041-3076","type":"electronic"}],"subject":[],"published":{"date-parts":[[2026,2,4]]},"article-number":"14644207261418507"}}