A laminate structure and method of forming is provided. The laminate structure includes a first metal sheet having a first thickness, a second metal sheet having a second thickness, and an adhesive core having an adhesive thickness. The adhesive core is disposed between and bonded to the first and second metal sheets. The first and second metal sheets are made of an aluminum based material and the adhesive core is made of an adhesive material also described as a viscoelastic adhesive material. The laminate structure is configured such that a ratio of the sum of the first and second thickness to the adhesive thickness is greater than either to one (8:1). The laminate structure including the viscoelastic adhesive core is characterized by a composite loss factor at 1,000 Hertz which is continuously greater than 0.1 within a temperature range of 25 degrees Celsius to 50 degrees Celsius.

Provided is a metal jointed body, joined by solid-phase joining in the atmosphere, in which no protrusion of molten joining material occurs, that improves dimensional stability. A metal jointed body is formed by (A) making Ag films of two metal laminated bodies opposed to each other, the metal jointed body being configured by sequentially laminating a Zn film and an Ag film on an Al substrate serving as a member to be joined, and (B) bringing the Ag films into contact with each other, then (C) heating is performed while pressurizing, and closely adhering and solid-phase joining the Ag films to each other. The completed metal jointed body is a portion where Al—Ag alloy layers are provided on both sides of an Ag—Zn—Al alloy layer to join the Al substrates to each other.

Brazing strip or sheet comprising: a core layer made of aluminum alloy; a brazing layer made of aluminum alloy, clad on at least one face of the core layer; optionally an intermediate layer made of aluminum alloy, clad on at least one face either between the core layer and the brazing layer or the core layer without any other layer on top; characterized in that the brazing layer alloy comprises, in mass percentages:
from 7 to 13% Si, at most 0.8% Fe, at most 0.45% Cu, at most 0.20% Mn, at most 0.15% Mg, at most 0.20% Zn, at most 0.20% Ti, at most 0.04% Bi, from 0.01 to 0.10% Y, from 0.01 to 0.10% Sn, remainder aluminum and impurities.

An interlayered structure for joining of dissimilar materials, includes a first material substrate, a second material substrate having a composition dissimilar from a composition of the first material substrate, and a plurality of interlayers disposed between the first material substrate and the second material substrate, including a first interlayer nearest to the first material substrate and a last interlayer nearest to the second material substrate. The first interlayer has a composition selected to have a maximum solid solubility within the composition of the first material substrate that is greater than or equal to the other interlayers' solubility within the composition of the first material substrate. The last interlayer has a composition selected to have a maximum solid solubility within the composition of the second material substrate that is greater than or equal to the other interlayers' solubility within the composition of the second material substrate. At least one of the plurality of interlayers is a sintered powder interlayer.

A method of resistance spot welding a workpiece stack-up that includes an aluminum workpiece and an overlapping adjacent steel workpiece so as to minimize the thickness of an intermetallic layer comprising Fe—Al intermetallic compounds involves providing reaction-slowing elements at the faying interface of the aluminum and steel workpieces. The reaction-slowing elements may include at least one of carbon, copper, silicon, nickel, manganese, cobalt, or chromium. Various ways are available for making the one or more reaction-slowing elements available at the faying interface of the aluminum and steel workpieces including being dissolved in a high strength steel or being present in an interlayer that may take on a variety of forms including a rigid shim, a flexible foil, a deposited layer adhered to and metallurgically bonded with a faying surface of the steel workpiece, or an interadjacent organic material layer that includes particles containing the reaction-slowing elements.

A method of resistance spot welding a workpiece stack-up that that includes an aluminum workpiece and an adjacent overlapping steel workpiece involves assembling the workpiece stack-up so that an intermediate metallurgical additive is positioned between the faying surfaces of the aluminum and steel workpieces. The intermediate metallurgical additive includes at least one of carbon, silicon, nickel, manganese, chromium, cobalt, or copper, and has the capability to counteract the growth and formation of Fe—Al intermetallic compounds within a molten metal weld pool created within the aluminum workpiece during resistance spot welding of the workpiece stack-up. In certain aspects of the disclosed method, the intermediate metallurgical additive may be one or more metallurgical additive deposits that are deposited onto the faying surface of the aluminum workpiece or the faying surface of the steel workpiece by an oscillating wire arc welding process.

The invention relates to a brazable three-layered aluminum composite material having at least three layers with at least two different aluminum alloys, whereby an inner layer of the at least three layers is an aluminum brazing layer made from an aluminum brazing alloy, the other layers are configured as covering layers and include at least one further aluminum alloy, wherein the at least one further aluminum alloy has a higher solidus temperature than the liquidus temperature of the aluminum brazing alloy. The individual covering layers have a thickness which exceeds the thickness of the aluminum brazing layer by at least a factor of 1.5, preferably by a factor of 5. The brazable aluminum composite material is simply structured, has good brazing properties for the production of butt-joint brazing connections, significantly reduces the risk of a ‘burning through’ of brazed-on components and provides sufficient mechanical properties.

A system and method of braze resistance spot welding of an aluminum component to a galvanized steel component involve providing an aluminum-side electrode having a first tip defining a rounded shape, providing a galvanized steel-side electrode having a second tip defining a flat shape, depositing a braze filler material between the aluminum and galvanized steel components at a desired location for a spot weld, performing a pre-heat including providing a first current across the electrodes for a first period such that the braze filler melts and removes a portion of a zinc coating from the galvanized steel component, and after performing the pre-heat, performing a spot weld between the aluminum and galvanized steel components by providing a second current across the electrodes for a second period such that the aluminum melts and the galvanized steel does not melt, wherein the second current is greater than the first current.

A method for joining heat transfer plates, comprising: applying a melting depressant composition on individual application areas of a first metal sheet, each application area comprising a mid-section and two end-sections; pressing ridges and grooves in the metal sheet, the ridges extending in a direction that extends between the end-sections of the application areas, such that the application areas are located on top of the ridges; bringing the metal sheet into contact with a second, pressed metal sheet, such that contact points are formed where the mid-sections of the application areas re located; heating the sheets until melted metal is formed at the application areas where the melting depressant composition is applied; and allowing the melted metal to solidify such that a joint is obtained at the contact points.

A coating for a carrier material made of a steel material for joining to an aluminum material includes a first sublayer on the core part side and a second sublayer on the outside. On average, the coating includes approximately 1 to 10 wt. % silicon and iron, the remainder being aluminum. The first sublayer at least approximately includes 42 wt. % iron, 11 wt. % silicon, and no more than approximately 45 wt. % aluminum, which constitutes the remainder, and has a thickness of no more than approximately 3.5 μm. The second sublayer includes approximately 1 to 10 wt. % silicon, the remainder being aluminum, and has a thickness of approximately 5 to approximately 95 μm.