Effect of Welding Heat Input on Residual Stresses at the Corrugated Interface of Aluminum/Steel Composite panels

Effect of Welding Heat Input on Residual Stresses at the Corrugated Interface of Aluminum/Steel Composite panels | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Effect of Welding Heat Input on Residual Stresses at the Corrugated Interface of Aluminum/Steel Composite panels wei zhang, Fei Zhao, Lifeng Ma, Sujuan Zhong, Peng Guo This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8609247/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study investigates thick aluminum/steel composite panels featuring wave-flat composite interfaces. This study employs a thermo-mechanical sequentially coupled numerical simulation method to systematically analyze the influence of welding thermal cycles on the temperature distribution and residual stress patterns at the interface.By establishing a finite element analysis framework based on the Goldak double ellipsoid heat source model, the spatiotemporal evolution characteristics of temperature and stress during the welding process were revealed.The simulation results closely match the experimental measurements, validating the reliability of the model.The results indicate that the residual stresses along the thickness direction are primarily governed by the welding heat input.When the heat input increased from 11,232 J/cm to 22,464 J/cm, the peak residual stress in the thickness direction rose by 164%.Excessive heat input leads to overgrowth of brittle intermetallic compound (IMC) layers at the aluminum/steel interface, significantly weakening the interface's tensile pull-off strength and tensile shear strength.This study elucidates the mechanism by which welding thermal cycles influence the thermo-mechanical coupling response at the aluminum/steel composite panel interface, providing theoretical foundations and engineering guidance for optimizing composite panel welding processes and enhancing their in-service performance. Aluminum/steel composite panel Welding heat input Corrugated interface Residual stress Full Text Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8609247","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":575518069,"identity":"61321da8-d4ee-4e7e-9f0e-3d46481617c8","order_by":0,"name":"wei 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