Development of CAE Methodology for Joining of Dissimilar Metals Using Cold Metal Transfer and Its Validation

Growing demands for fuel efficient vehicles and reducing air pollution leads to light weighting of vehicles. Using optimum combination of high strength steel and lightweight aluminum alloy in the automotive structures may be answer to the problem.

Joining of these two dissimilar metals have several issues related to techniques and reliability that need to be addressed for efficient mass production. There are several joining techniques used for dissimilar metals out of which Cold Metal transfer (CMT) is one of the methods. As simulation is an integral part of product design, development of CAE methodology for joining of dissimilar metals using CMT is necessary.

This paper includes investigation on various modeling methods of welded joint developed using CMT process. Numbers of lap shear specimen were tested experimentally and results were compared with simulation. Based on correlation, most suited modeling technique was adopted.