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Computational and Experimental Insights into Zinc-Coating Dynamics for Dissimilar Impact Welding of Galvannealed Steel-Aluminum Joints.

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Title: Computational and Experimental Insights into Zinc-Coating Dynamics for Dissimilar Impact Welding of Galvannealed Steel-Aluminum Joints.
Authors: Kumar, Deepak1 (AUTHOR), Choi, Jungyu1 (AUTHOR), Lim, Hyeonbeom1 (AUTHOR), Kwon, Hyuckmin2 (AUTHOR), Jeong, Junyeong2 (AUTHOR), Kim, Yongshin3 (AUTHOR), Lee, Taeseon1 (AUTHOR) taelee19@inu.ac.kr
Source: Journal of Materials Engineering & Performance. Mar2026, Vol. 35 Issue 12, p12203-12216. 14p.
Subjects: Dissimilar welding, Galvanizing, Welding, Lightweight construction, Aluminum alloy welding, Steel, Computational fluid dynamics, Interfacial bonding
Abstract: Dissimilar welding of galvannealed steel and aluminum alloys remains a critical challenge in automotive lightweighting due to zinc (Zn) coating-induced interfacial complexities. This study integrates smoothed particle hydrodynamics (SPH) modeling with vaporizing foil actuator welding (VFAW) experiments to unravel the role of Zn coatings in A6451-SGACC steel joint performance. Computational simulations, upon comparison with SEM and EDS results, reveal how localized Zn melting and jetting dynamics govern interfacial heterogeneity, correlating with experimental observations of retained Zn layers, trapped oxides, and incomplete metallurgical bonding. SPH-based predictive modeling elucidates how jet-induced stripping, melt backflow, and vaporization govern zinc transport during high-velocity impact. Clean-bonded regions exhibit complete zinc ejection and sharp Al-Fe contact, enabling a mean lap-shear peak load of 6.32 kN, whereas Zn-rich interlayers suppress interfacial waviness and initiate cross-tension failure with a mean cross-tension peak load of 0.92 kN, corresponding to an ~ 85% reduction relative to lap-shear. SPH modeling accurately captures zinc bilayer dynamics and highly localized temperature spikes (> 900 K) confined to the jetting/impact-front region, i.e., ~ 170% higher than the surrounding interface, validating experimental observations. These insights address a critical gap in joining coated dissimilar materials and inform the design of reliable, lightweight automotive structures. [ABSTRACT FROM AUTHOR]
Copyright of Journal of Materials Engineering & Performance is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
An: 192619720
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PubTypeId: academicJournal
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  Data: Computational and Experimental Insights into Zinc-Coating Dynamics for Dissimilar Impact Welding of Galvannealed Steel-Aluminum Joints.
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  Data: <searchLink fieldCode="AR" term="%22Kumar%2C+Deepak%22">Kumar, Deepak</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Choi%2C+Jungyu%22">Choi, Jungyu</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Lim%2C+Hyeonbeom%22">Lim, Hyeonbeom</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kwon%2C+Hyuckmin%22">Kwon, Hyuckmin</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Jeong%2C+Junyeong%22">Jeong, Junyeong</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kim%2C+Yongshin%22">Kim, Yongshin</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Lee%2C+Taeseon%22">Lee, Taeseon</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> taelee19@inu.ac.kr</i>
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+Materials+Engineering+%26+Performance%22">Journal of Materials Engineering & Performance</searchLink>. Mar2026, Vol. 35 Issue 12, p12203-12216. 14p.
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  Data: <searchLink fieldCode="DE" term="%22Dissimilar+welding%22">Dissimilar welding</searchLink><br /><searchLink fieldCode="DE" term="%22Galvanizing%22">Galvanizing</searchLink><br /><searchLink fieldCode="DE" term="%22Welding%22">Welding</searchLink><br /><searchLink fieldCode="DE" term="%22Lightweight+construction%22">Lightweight construction</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloy+welding%22">Aluminum alloy welding</searchLink><br /><searchLink fieldCode="DE" term="%22Steel%22">Steel</searchLink><br /><searchLink fieldCode="DE" term="%22Computational+fluid+dynamics%22">Computational fluid dynamics</searchLink><br /><searchLink fieldCode="DE" term="%22Interfacial+bonding%22">Interfacial bonding</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Dissimilar welding of galvannealed steel and aluminum alloys remains a critical challenge in automotive lightweighting due to zinc (Zn) coating-induced interfacial complexities. This study integrates smoothed particle hydrodynamics (SPH) modeling with vaporizing foil actuator welding (VFAW) experiments to unravel the role of Zn coatings in A6451-SGACC steel joint performance. Computational simulations, upon comparison with SEM and EDS results, reveal how localized Zn melting and jetting dynamics govern interfacial heterogeneity, correlating with experimental observations of retained Zn layers, trapped oxides, and incomplete metallurgical bonding. SPH-based predictive modeling elucidates how jet-induced stripping, melt backflow, and vaporization govern zinc transport during high-velocity impact. Clean-bonded regions exhibit complete zinc ejection and sharp Al-Fe contact, enabling a mean lap-shear peak load of 6.32 kN, whereas Zn-rich interlayers suppress interfacial waviness and initiate cross-tension failure with a mean cross-tension peak load of 0.92 kN, corresponding to an ~ 85% reduction relative to lap-shear. SPH modeling accurately captures zinc bilayer dynamics and highly localized temperature spikes (> 900 K) confined to the jetting/impact-front region, i.e., ~ 170% higher than the surrounding interface, validating experimental observations. These insights address a critical gap in joining coated dissimilar materials and inform the design of reliable, lightweight automotive structures. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Journal of Materials Engineering & Performance is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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      – SubjectFull: Galvanizing
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      – SubjectFull: Welding
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      – SubjectFull: Lightweight construction
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      – SubjectFull: Aluminum alloy welding
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      – SubjectFull: Steel
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      – TitleFull: Computational and Experimental Insights into Zinc-Coating Dynamics for Dissimilar Impact Welding of Galvannealed Steel-Aluminum Joints.
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              Text: Mar2026
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