为了实现铝/钢复合结构的灵活制造，提出了“电弧 + 搅拌摩擦”复合增材制造的新方法，即先利用旁路分流熔化极惰性气体保护焊在镀锌的Q235钢表面沉积一层薄的铝合金过渡层，再搅拌摩擦增材制造过渡层和6061铝合金. 在电弧沉积过渡层过程中，镀锌层和旁路电弧促进了液滴在钢表面的润湿性和铺展性，获得了平整的表面成形，随后的搅拌摩擦增材制造过程消除了过渡层的气孔和裂纹缺陷，获得了表面成形良好且无缺陷的铝/钢复合结构. 研究了不同焊丝成分(Al-Si，Al-Mg)对铝/钢复合结构的组织和耐腐蚀性能影响,结果表明，焊丝成分不会影响焊缝成形，但会影响界面金属间化合物层厚度，Al-Si焊丝的Si元素偏聚在铝/钢界面层附近，可以有效阻止Fe，Al元素的相互扩散, 减少金属间化合物的产生.同时填充Al-Si焊丝的铝/钢结构耐腐蚀性好于填充Al-Mg焊丝，这是因为受到界面层金属间化合物的影响，金属间化合物会和基体发生电偶腐蚀，优先腐蚀铝基体，降低铝/钢复合结构耐腐蚀性能.
In order to realize the manufacturing of aluminum-steel composite structures, this study proposed a new method of "arc + friction stir" hybrid additive manufacturing. First, BC-MIG welding is applied to deposit a thin transition layer of aluminum alloy on the surface of galvanized Q235 steel, and after which the transition layer and the the 6061 aluminum alloy is produced by friction stir additive manufacturing. During the arc deposition of the transition layer, the galvanized layer and the bypass arc have promoted the wetting and spreading of droplets on the steel surface, thus help to form a flat surface.The subsequent friction stir additive manufacturing process eliminated porosity and cracks in the transition layer and brought about a well-formed and defect-free aluminum-steel composite structure.The effects of different wire compositions (Al-Si and Al-Mg) on the microstructure and corrosion resistance of Al-steel composite structures were investigated.The results showed that the wire composition, instead of affecting the weld formation, will affect the thickness of the Fe-Al intermetallic compounds layer at the interface. Besides, the corrosion resistance of Al-steel structures filled with Al-Si wire is better than that with Al-Mg wire, as galvanic corroion will occur among the intermetallic compounds at the interface, while the substrate is tend to be corroded first, so that the corrosion resistance of the Al-steel composite structure is decreased.
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