Effect of Ni Foil on Laser Fusion Welding Microstructure and Mechanical Properties of SUS301L / 6061 dissimilar joints

Effect of Ni Foil on Laser Fusion Welding Microstructure and Mechanical Properties of SUS301L / 6061 dissimilar joints | 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 Ni Foil on Laser Fusion Welding Microstructure and Mechanical Properties of SUS301L / 6061 dissimilar joints liu zuguo, Yu Chaojing, Zhong Yinliang, Hao Zhongjia This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8456166/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract The presence of brittle Fe-Al intermetallic compounds (IMC) limits the performance of steel / aluminum joints. In this paper, Ni foil will be used as an intermediate layer in SUS301L (Fe) / 6061 aluminum (Al) dissimilar overlap laser welding to suppress the generation of IMC at the Fe-Al interface. Explored the influence of Ni interlayer on joint strength, joint microstructure composition, and element distribution, and analyzed the effect of Ni foil in the welding process. The results of the composition and distribution of various elements in the weld microstructure indicate that the introduction of Ni foil significantly improves the phase composition of the brittle layer at the weld interface, forming NiAl/NiAl3 ductile phase compounds, indicating that the reaction between Fe and Al is suppressed. In addition, it was found that the thickness of Ni foil has a significant impact on the formation of Fe-Al IMC. After adding Ni foil with a thickness of 0.05mm, the maximum load value reached 498.03N. Compared to the situation without Ni foil, which one has increased by 47.45%. Through EDS testing of tensile fractures, it was found that the mechanical properties of the joint largely depend on the ductility/brittleness of IMCs. Fe/Al Laser fusion welding Ni foil Intermetallic compounds Mechanical properties Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 29 Jan, 2026 Reviewers invited by journal 28 Jan, 2026 Editor invited by journal 06 Jan, 2026 Editor assigned by journal 30 Dec, 2025 First submitted to journal 28 Dec, 2025 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. 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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-8456166","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":581931335,"identity":"5098459e-751d-4a85-b9ce-e71e81b7ec7c","order_by":0,"name":"liu zuguo","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA40lEQVRIie3RsQrCMBCA4SuFdDl0jVTqK6QUOgn6KA2FTgodOzgoih1UXDv4EI6OFiFT3DtWfAHdHAS1s2Lq5pBvzk9yFwBN+0PEmubnGyPYsdK8DJKROmmgCD2IG213KUNWSqFOHDrwbbg4XSj6fus0M2s8DPeeFzMfjQyihI8JNNNFoJhlzM8Zi9CyJ6LguzZQedyqbjkwZAKNzT4quCTA6FCRUD6nyB4IReDHfG7WSUJi42vJVQL1EhSmm72Sask0kAKVs3TS9bW83Emv+srrLRk5zXT1PXmDvx3XNE3TPnoCrSxIooVVI68AAAAASUVORK5CYII=","orcid":"","institution":"Guizhou University","correspondingAuthor":true,"prefix":"","firstName":"liu","middleName":"","lastName":"zuguo","suffix":""},{"id":581931336,"identity":"304bdcaa-2167-4064-87c4-682c50b677b2","order_by":1,"name":"Yu Chaojing","email":"","orcid":"","institution":"Moutai Institute","correspondingAuthor":false,"prefix":"","firstName":"Yu","middleName":"","lastName":"Chaojing","suffix":""},{"id":581931337,"identity":"374b12f7-a220-4b4d-9cb7-e1ee71537ffa","order_by":2,"name":"Zhong Yinliang","email":"","orcid":"","institution":"Moutai Institute","correspondingAuthor":false,"prefix":"","firstName":"Zhong","middleName":"","lastName":"Yinliang","suffix":""},{"id":581931338,"identity":"1a0f16c6-5611-4520-b4fa-62df1b24855a","order_by":3,"name":"Hao Zhongjia","email":"","orcid":"","institution":"Shihezi University","correspondingAuthor":false,"prefix":"","firstName":"Hao","middleName":"","lastName":"Zhongjia","suffix":""}],"badges":[],"createdAt":"2025-12-26 14:55:21","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-8456166/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8456166/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":101522209,"identity":"01d644e4-e33e-4c93-ba72-dea38cf91dc2","added_by":"auto","created_at":"2026-01-30 17:26:19","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1295431,"visible":true,"origin":"","legend":"","description":"","filename":"paper.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8456166/v1_covered_aa3967f1-f7a3-4bf4-b8b1-1c72a6b66808.pdf"}],"financialInterests":"","formattedTitle":"Effect of Ni Foil on Laser Fusion Welding Microstructure and Mechanical Properties of SUS301L / 6061 dissimilar joints","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Fe/Al Laser fusion welding, Ni foil, Intermetallic compounds, Mechanical properties ","lastPublishedDoi":"10.21203/rs.3.rs-8456166/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8456166/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe presence of brittle Fe-Al intermetallic compounds (IMC) limits the performance of steel / aluminum joints. In this paper, Ni foil will be used as an intermediate layer in SUS301L (Fe) / 6061 aluminum (Al) dissimilar overlap laser welding to suppress the generation of IMC at the Fe-Al interface. Explored the influence of Ni interlayer on joint strength, joint microstructure composition, and element distribution, and analyzed the effect of Ni foil in the welding process. The results of the composition and distribution of various elements in the weld microstructure indicate that the introduction of Ni foil significantly improves the phase composition of the brittle layer at the weld interface, forming NiAl/NiAl3 ductile phase compounds, indicating that the reaction between Fe and Al is suppressed. In addition, it was found that the thickness of Ni foil has a significant impact on the formation of Fe-Al IMC. After adding Ni foil with a thickness of 0.05mm, the maximum load value reached 498.03N. Compared to the situation without Ni foil, which one has increased by 47.45%. Through EDS testing of tensile fractures, it was found that the mechanical properties of the joint largely depend on the ductility/brittleness of IMCs.\u003c/p\u003e","manuscriptTitle":"Effect of Ni Foil on Laser Fusion Welding Microstructure and Mechanical Properties of SUS301L / 6061 dissimilar joints","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-01-30 17:26:02","doi":"10.21203/rs.3.rs-8456166/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2026-01-29T16:21:16+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2026-01-28T16:04:25+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"Welding in the World","date":"2026-01-06T07:56:46+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-12-30T07:33:47+00:00","index":"","fulltext":""},{"type":"submitted","content":"Welding in the World","date":"2025-12-29T03:10:23+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"795fa890-ff9b-4c79-9fab-5b53c6b3dac7","owner":[],"postedDate":"January 30th, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-01-30T17:26:02+00:00","versionOfRecord":[],"versionCreatedAt":"2026-01-30 17:26:02","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8456166","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8456166","identity":"rs-8456166","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}