Dissimilar Friction Stir Welding between Magnesium and Aluminum Alloys
محورهای موضوعی : Precision manufacturing processes and systems
1 - Materials Science and Engineering Dept., Islamic Azad University, Sirjan Branch
کلید واژه: Friction Stir Welding, Rotation speed, Al alloy, Mg alloy,
چکیده مقاله :
Joining two dissimilar metals, specifically Mg and Al alloys, using conventional welding techniques is extraordinarily challenging. Even when these alloys can be joined, the weld is littered with defects such as cracks, cavities, and wormholes. The focus of this study was to use friction stir welding to create a defect-free joint between Al 2139 and Mg WE43. The design included an 11 mm scrolled and concave shoulder in addition to a 6 mm length pin comprised of two tapering, threaded re-entrant flutes that promoted and amplified material flow. Upon completion of this project, an improved experimental setup process was created as well as successful welds between the two alloys. These successful joints, albeit containing defects, lead to the conclusion that the tool used in the project was ill-fit to join the Al and Mg alloy plates. As a result of this aggressive pin design, there was a lack of heat generation towards the bottom of the pin even at higher (800-1000 rpm) rotation speeds. This lack of heat generation prohibited the material from reaching plastic deformation thus preventing the needed material flow to form the defect-free joint.
[1] Sameer, M. and Anil Kumar, B. 2019. Mechanical and metallurgical properties of friction stir welded dissimilar joints of AZ91 magnesium alloy and AA 6082-T6 aluminium alloy. Journal of Magnesium and Alloys. 7: 264-271.
[2] Rajendran, C. and Srinivasan, K. 2019. Effect of tool tilt angle on strength and microstructural characteristics of friction stir welded lap joints of AA2014-T6 aluminum alloy. Transactions of Nonferrous Metals Society of China. 29: 1824-1835.
[3] Peiqi, L., Guoqiang, Y., Hengyu, W. and Sha, L. 2019. Friction stir welding between the high-pressure die casting of AZ91 magnesium alloy and A383 aluminum alloy. Journal of Materials Processing Technology. 264: 55-63.
[4] Boccarusso, L., Astarita, A. and Carlone, P. 2019. Dissimilar friction stir lap welding of AA 6082 - Mg AZ31: Force analysis and microstructure evolution. Journal of Manufacturing Processes. 44: 376-388.
[5] Jedrasiak, P. and Shercliff, H. 2019. Small strain finite element modelling of friction stir spot welding of Al and Mg alloys. Journal of Materials Processing Technology. 263: 207-222.
[6] Sato, Y., Park, S. and Kokawa, H. 2001. Microstructural factors governing hardness in friction-stir welds of solid-solution-hardened Al alloys. Metallic Materials Transactions. 32:3033–3042.
[7] Yan, J., Sutton. A. and Reynolds. A. 2005. Process structure property relationships for nugget and heat affected zone regions of AA2524-T351 friction stir welds, Science and Technology of Welding and Joining, 10: 725-36.
[8] Yamamoto, N., Liao, J., Watanabe, S. and Nakata, K. 2009. Effect of intermetallic compound layer on tensile strength of dissimilar friction-stir weld of high strength Mg alloy and Al Alloy. Materials Transactions. 50: 2833-2838.
[9] Jagadeesha, C. 2014. Dissimilar friction stir welding between aluminum alloy and magnesium allow at a low rotational speed, Materials Science and Engineering A. 616: 55-62.
[10] Shibayanagi, S., Khodir, A. and Toshiya, D. 2007. Microstructure and Mechanical Properties of Friction Stir Welded Dissimilar Aluminum Joints of AA2024-T3 and AA7075-T6, Materials Transactions. 48: 1928-1937.
[11] Magnesium Elektron WE43 Alloy. AZO Materials. http://www.azom.com/article.aspx?ArticleID=9279.
[12] Cho, A., Lisagor, W. and Bales, T. 2007. Development and Processing Improvement of Aerospace Aluminum Alloys - Development of Al-Cu-Mg-Ag Alloy (2139), NASA/CR. 27:215-294.
[13] Das, J., Banik, S., Reddy, S., Sankar, M. and Robi, P. 2019. Review on process parameters effect on fatigue crack growth rate in friction stir welding. Materials today processing. 18: 3061-3070.
[14] Guangyu, L., Wenming, J., Feng, G., Junwen, Z. and Zitian, F. 2021, Microstructure, mechanical properties and corrosion resistance of A356 aluminum/AZ91D magnesium bimetal prepared by a compound casting combined with a novel Ni-Cu composite interlayer. Journal of Materials Processing Technology. 288: 116-128.
[15] Chunliang, Y., Chuan, S. and Wu, L. 2020, Modeling the dissimilar material flow and mixing in friction stir welding of aluminum to magnesium alloys. Journal of Alloys and Compounds. 843:156-162.
[16] Raval, S. and Judal, K. 2020. Recent Advances in Dissimilar Friction Stir Welding of Aluminum to Magnesium Alloys. Materials today processing. 22: 2665-2675.
