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Microstructural Analysis of Diffusion-Bonded AZ31 Mg Alloy Fabricated by Wire-Arc-Directed Energy Deposition for Lightweight Complex Structures

  • Phase Transformation and Microstructure Evolution during Thermomechanical Processing
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Abstract

Additive manufacturing is gaining wide acceptance in the manufacturing industries, but the joining of additively manufactured components is a rarely researched area. In this study, diffusion bonding of directed energy-deposited (DED) Mg alloy (AZ31), using an electric arc as an energy source was analyzed. Diffusion bonding (DB) was performed in a non-vacuum condition with gallium treatment at the faying surfaces to eliminate the oxide formation and promote metallurgical contact. Microstructural and elemental distribution analyses of additively manufactured AZ31 alloy and diffusion-bonded joints were carried out using FESEM and EPMA. EBSD analysis indicated that the bonding interface is characterized by discontinuous dynamic recrystallized grains featured by grain boundary bulging and grain boundary migration. The 90° triple junction observed at the interface migrates to reduce the grain boundary energy. The fine precipitates of β-Mg17Al12 were distributed uniformly throughout the material, which enhanced precipitation hardening. High integrity joints without any voids could be obtained by diffusion bonding and the joint line was not discernible. The high-intensity elemental content at the joint interface highlights the enhanced interdiffusion of constituent atoms across the faying surfaces.

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Acknowledgement

The authors acknowledge the central research facility at IIT Delhi for use of the FESEM TESCAN and EPMA facilities and Prof. Suresh Neelakantan, Department of Materials Science and Engineering, IIT Delhi for providing EBSD facility.

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  1. Department of Mechanical Engineering, IIT Delhi, New Delhi, 110016, India

    R. Dipin Kumar, Yashwant Koli & S. Aravindan

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  1. R. Dipin Kumar
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  2. Yashwant Koli
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Correspondence to S. Aravindan.

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Kumar, R.D., Koli, Y. & Aravindan, S. Microstructural Analysis of Diffusion-Bonded AZ31 Mg Alloy Fabricated by Wire-Arc-Directed Energy Deposition for Lightweight Complex Structures. JOM (2024). https://doi.org/10.1007/s11837-024-06582-7

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  • DOI: https://doi.org/10.1007/s11837-024-06582-7

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