The mechanism of the interface layer formation between steel and aluminum dissimilar materials is unclear by now. An interfacial bonding was investigated by joining steel sheets to 6061 aluminum sheets under a thermal and mechanical coupled loading. The effects of temperature and zinc coating on microstructural evolution and shear strength of the interface layer were both studied. The experimental results showed that the interface layer between the uncoated steel and aluminum was mainly composed of FeAl₃ intermetallic compound (IMC). The shear strength of the joint increased with temperature. The existence of the zinc coating was able to lower the temperature to form the interface layer and improve its shear strength. The interface layer between the zinc coated steel and aluminum was mainly composed of Fe₂Al₅Zn_x and Al-Zn eutectic phases with a lower micro hardness. That suggested that the brittleness of the interface layer composed of the Fe-Al IMC could be avoided by modify the zinc coating and temperature. A zinc foil was added between steel and aluminum sheets to amplify the interface layer for microstructure observation. Based on the results an interface bonding model of steel and aluminum dissimilar materials considering the temperature and zinc coating was proposed.

目前尚不清楚钢和铝异种材料之间界面层形成的机理。通过在热和机械耦合载荷下将钢板连接到6061铝板上，研究了界面粘结。研究了温度和镀锌层对界面层组织演变和剪切强度的影响。实验结果表明，未涂层钢与铝之间的界面层主要由FeAl ₃金属间化合物（IMC）组成。接头的剪切强度随着温度的升高而增加。锌涂层的存在能够降低形成界面层的温度并提高其剪切强度。镀锌钢与铝之间的界面层主要由铁组成具有较低显微硬度的₂ Al ₅ Zn _x和Al-Zn共晶相。这表明，通过改变镀锌层和温度可以避免由Fe-Al IMC组成的界面层的脆性。在钢片和铝片之间添加锌箔，以放大界面层，以进行微观结构观察。根据结果​​，提出了考虑温度和镀锌层的钢和铝异种材料的界面结合模型。