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Liquation Cracking in Arc and Friction-Stir Welding of Mg-Zn Alloys

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Abstract

As compared to Al alloys, which are known to be susceptible to liquation (i.e., liquid formation) and liquation-induced cracking, most Mg alloys have a lower eutectic temperature and thus are likely to be even more susceptible. The present study was conducted to study liquation and liquation cracking in Mg alloys during arc welding and friction-stir welding (FSW). Binary Mg-Zn alloys were selected as a model material in view of their very low eutectic temperature of 613 K (340 °C). Mg-Zn alloys with 2, 4, and 6 wt pct of Zn were cast and welded in the as-cast condition by both gas-tungsten arc welding (GTAW) and FSW. A simple test for liquation cracking was developed, which avoided interference by solidification cracking in the nearby fusion zone. Liquation and liquation cracking in GTAW were found to be in the decreasing order of Mg-6Zn, Mg-4Zn, and Mg-2Zn. Liquation cracking occurred in FSW of Mg-6Zn but not Mg-4Zn or Mg-2Zn. Instead of a continuous ribbon-like flash connected to the weld edge, small chips, and powder covered the weld surface of Mg-6Zn. The results from GTAW and FSW were discussed in light of the binary Mg-Zn phase diagram and the curves of temperature vs fraction solid during solidification.

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Acknowledgments

This work was supported by the National Science Foundation under Grant No. IIP-1034695 and the University of Wisconsin Foundation through the Industry/University Collaborative Research Center (I/UCRC) for Integrated Materials Joining Science for Energy Applications. The authors would like to thank CompuTherm, LLC in Madison, WI and Professor Rainer Schmid-Fetzer, Clausthal University of Technology at Clausthal-Zellerfeld, Germany for the software package Pandat and the database PanMg. The authors would like to thank Mr. Tom Kurilich of US Magnesium LLC in Salt Lake City, Utah for donating 45 kg (100 lbs) of pure Mg ingots. They would also like to thank the late John F. Hinrichs of Friction Stir Link, Inc., Menomonee Falls, WI for suggesting the topic for study.

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Author notes

  1. Dustin C. Wagner (Former Graduate Student)

    Present address: Miller Electric Mfg. Co., Appleton, WI, USA

  2. Xin Tang (Formerly Visiting Professor, Professor)

    Present address: Guilin University of Technology, Guilin, P.R. China

Authors and Affiliations

  1. Department of Materials Science and Engineering, The University of Wisconsin, Madison, WI, 53706, USA

    Dustin C. Wagner (Former Graduate Student), Xiao Chai (Graduate Student), Xin Tang (Formerly Visiting Professor, Professor) & Sindo Kou (Professor)

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  1. Dustin C. Wagner
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  2. Xiao Chai
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Correspondence to Sindo Kou.

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Manuscript submitted April 7, 2014.

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Wagner, D.C., Chai, X., Tang, X. et al. Liquation Cracking in Arc and Friction-Stir Welding of Mg-Zn Alloys. Metall Mater Trans A 46, 315–327 (2015). https://doi.org/10.1007/s11661-014-2606-5

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