PSI - Issue 79

Benjamin Möller et al. / Procedia Structural Integrity 79 (2026) 493–500

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• Under tensile loading, the adapter reaches max. tensile forces in the range of F t = 35 kN, which exceeds the yield strength of the aluminum alloy AA5083 by approximately 37 %. Final failure occurs outside the steel-aluminum joint in the connecting fillet weld using GMAW from aluminum T-profile to the aluminum sheet, so that resistance against tensile loading has been proven. • Fatigue testing shows increase fatigue strength against previous adapter design without form fit and advantageous microstructure from Möller et al. (2019) in a factor of 2 to 3 in the range 1·10 5 ≤ N f ≤ 5·10 6 . Furthermore, robustness towards welding process parameter variations resulting in weld geometry variations was found from the investigation. Additionally, camera tracking and DIC are valuable methods for analysis of the strain field as well as crack initiation and propagation. • Based on the random sample of three corrosion fatigue tests in the range 4·10 5 ≤ N f ≤ 5·10 6 , no negative effect of corrosive media (NaCl solution) on the adapters could be identified. In Comparison, a fatigue strength reduction of 10 % to 20 % in the high cycle fatigue regime was found for the steel-aluminum adapters in Möller et al. (2019). Corrosion fatigue should be addressed with respect to the final application and its boundary conditions. Acknowledgements The work presented was carried out within the scope of the German joint research project FOLAMI “Laser beam welding of form fit dissimilar joints of steel and aluminum for serviceable semi- finished products in shipbuilding” (”Formschl üssiges Laserstrahlschweißen der Mischverbindung aus Stahl und Aluminium für betriebsfeste Halbzeuge im Schiffbau”). This project (Reference No. 03SX547) was funded by the Federal Ministry for Economic Affairs and Energy (BMWE), within the framework of the funding line “Next generation maritime technologies” (“Maritime Technologien der nä chsten Generation”) of the German Federal Government and supervised by the Project Management Jülich (PtJ), which is gratefully acknowledged. Furthermore, the authors would like to thank the project partners and the project committee member companies, as well as their representatives, for supporting the project and for their good cooperation. References Buijs, K., 2004. Triplate: The ultimate solution for welding aluminum to steel. HSB International (2004) DINENISO9227, 2017. Corrosion tests in artificial atmospheres – Salt spray tests (ISO 9227:2017); German version ENISO 9227:2017. DIN Deutsches Institut für Normung e. V., Berlin (2017) Klock, H., Schroer, H., 1977. Schweißen und Löten von Aluminiumwerkstoffen. Deutscher Verlag für Schweißtechnik, Düsseldorf (1977) Korschinsky, T., Lahdo, R., Möller, B., Baumgartner, J., Sarah, S., Hermsdorf, J., Kaierle, S., 2025. Static and fatigue strength of laser-beam welded steel-aluminium lap joints, IIW Document XIII-3167-2025 and Welding in the World (under review) Kreimeyer, M., Beckmann, M., Wagner, F., Vollertsen, F., 2004. Umformen lasergefügter Fe/Al- und Ti/AlTailored Hybrid Blanks. 11 th Sächsische Fachtagung für Umformtechnik, October 2004, Freiberg, pp. 343-343 Lahdo, R., Springer, A., Pfeifer, R., Kaierle, S., Overmeyer, L., 2016. High-power laser welding of thick steel-aluminum dissimilar joints. Physics Procedia 83 (2016), pp. 396-405; doi: 10.1016/j.phpro.2016.08.041 Lahdo, R., Springer, A., Meier, O., Kaierle, S., Overmeyer, L., 2018. Investigations on laser welding of dissimilar joints of steel and aluminum using a high-power diode laser. Journal of Laser Applications 30 (2018) Lahdo, R. Laser beam welding of steel to aluminium alloys in thick sheet range. Ph.D. thesis, Gottfried Wilhelm Leibniz Universität Hannover, Garbsen, Germany (2021). Dissertation Lahdo, R., Seffer, S., Seffer, O. Hermsdorf, J., Kaierle, S., 2023. Investigations on improving the properties of laser beam welded thick dissimilar joints of steel and aluminum by using filler material, Journal of Laser Applications 35, 042011 (2023); doi: 10.2351/7.0001172 Lahdo, R., Seffer, S., Seffer, O. Hermsdorf, J., Kaierle, S., 2025. In-process control of penetration depth for welding of dissimilar joints of steel and aluminum with two intersecting laser beams, Journal of Laser Applications 37, 022018 (2025). doi: 10.2351/7.0001603 Lipiäinen, K., Afkhami, S., Havia, J., Ahola, A., Moshtaghi, M., Björk, T., 2025. Fatigue performance of explosion-cladded steel-to-aluminium transition joints for marine applications, Welding in the World 69, 2323 – 2333 528 (2025); doi: doi.org/10.1007/s40194-025-02029-y Möller, B., Wagener, R., Melz, T., Lahdo, R., Springer, A., Kaierle, S., 2017. Strength analysis of laser beam welded steel-aluminium joints for maritime light weight applications. Proceedings of the 7th International Conference on Mechanics and Materials in Design (2017) Möller, B., Albrecht, S., Wagener, R., Melz, T., 2019 Fatigue strength of laser beam welded steel-aluminium joints considering variable amplitude loading and corrosive environment. Procedia Structural Integrity 18 (2019) pp. 556 – 569; doi: doi.org/10.1016/j.prostr.2019.08.200