Experimental Investigation and Optimization on the Process Parameters during Induction Pressure Welding for Steel and Aluminum Alloy Using Response Surface Method

A novel welding method, induction pressure welding (IPW) process was used to join steel and aluminum alloy. The effects of input power, air gap and heating time on welding point width, intermetallic compound (IMC) thickness and tensile strength were investigated during the IPW process using response surface method. The results indicate that the heating time has the most marked effect on micro-structure and mechanical performance in all single factors. The air gap and heating time have the greatest interaction effect on tensile strength and welding point width while the input power and heating time have the greatest interaction influence on IMC thickness. The most desirable process parameters with input power 30kW, air gap 4.4mm, and heating time 10s are expected to be able to minimize IMC thickness and maximize tensile strength. The comparison between the predicted and experimental results for tensile strength and IMC thickness indicates that the mathematical model built by response surface method is reliability.