Welding Aluminium In Steel. To avoid this you must isolate the other metal from the molten aluminum during the arc welding. You can weld aluminum to most other metals relatively easily via adhesive bonding or mechanical fastening.
Steels can be joined to Aluminum alloys relatively only using metal brazing or mechanical fasteners like a stud welder and adhesive bonding. When metals such as steel copper magnesium or titanium are directly arc welded to aluminum very brittle intermetallic compounds start to form. Once the metals have cooled the materials will have been successfully bonded to one another.
The melting point of aluminum is much lower than that of steel 1221 degrees Fahrenheit for aluminum compared to 2500 degrees for steel.
To avoid this you must isolate the other metal from the molten aluminum during the arc welding. This avoids overheating due to different melting points. Steels can be joined to Aluminum alloys relatively only using metal brazing or mechanical fasteners like a stud welder and adhesive bonding. To reduce costs manufacturers weld flange components made of aluminium to galvanised steel plates so that they can be joined using the conventional cost-effective spot welding process on the bodyshell production line.