A Review on Metallurgical and Mechanical Issues in Al/Steel Transition Joints Produced by Explosive Welding

Transition joints between lightweight aluminum alloys and high-strength steel are widely employed in the transportation industry, and especially in shipbuilding, as intermediate inserts between structural components made of dissimilar metals. While traditional fusion welding presents considerable difficulties in joining such metals, explosive welding is particularly suitable for producing thick plates with large contact surfaces between aluminum and steel. The process setup and the various parameters involved have been described in several articles, as also documented by some recent overviews. However, there has been no review of the most recent papers specifically dealing with the metallurgical characteristics of these interfaces, as well as with their mechanical properties. Thus, the present article aims to fill this gap by outlining a review on the state of the art to correlate the process parameter setting, interface characteristics, and weldability of aluminum/steel transition joints, and then focusing on the most relevant studies concerning the mechanical behavior under static and fatigue conditions of trimetallic joints (Al alloy/commercially pure Al/structural steel) for shipbuilding applications. The effects of welding-induced thermal fields during structural joint insertion are also taken into account, and the most recent proposals for strategies to improve mechanical performance are examined.