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Friction Stir Lap Welding of Magnesium Alloy to Steel: A Preliminary Investigation

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Abstract

An initial study was made to evaluate the feasibility of joining magnesium alloy AZ31 sheet to galvanized steel sheet in a lap configuration using friction stir welding (FSW). Two different automotive sheet steels were used for comparative evaluation of the dissimilar joining potential: a 0.8 mm thick, electrogalvanized (EG) mild steel, and a 1.5 mm thick hot-dipped galvanized (HDG) high-strength, low-alloy (HSLA) steel. These steels were joined to 2.33 mm thick AZ31B magnesium sheet. A single FSW tool design was used for both dissimilar welds, and the process parameters were kept the same. The average peak load for the AZ31-1.5 mm steel weld joint in lap shear mode was found to be 6.3 ± 1.0 kN. For the AZ31-0.8 mm steel weld, joint strength was 5.1 ± 1.5 kN. Microstructural investigation indicates melting of the Zn coating present on the steel sheets, and subsequent alloying with the Mg sheet resulted in the formation of a solidified Zn-Mg alloy layer.

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Acknowledgments

This manuscript was authored by Battelle Memorial Institute, Pacific Northwest Division, under Contract No. DE-AC05-76RL01830 with the United States Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes.

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Authors and Affiliations

  1. Energy and Environment Directorate, Pacific Northwest National Laboratory, Richland, WA, 99352, USA

    S. Jana (Postdoctoral Research Associate), Y. Hovanski (Engineer) & G.J. Grant (Scientist)

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  1. S. Jana
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  2. Y. Hovanski
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  3. G.J. Grant
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Correspondence to S. Jana.

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U.S. GOVERNMENT WORK NOT PROTECTED BY U.S. COPYRIGHT

Manuscript submitted February 4, 2010.

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Jana, S., Hovanski, Y. & Grant, G. Friction Stir Lap Welding of Magnesium Alloy to Steel: A Preliminary Investigation. Metall Mater Trans A 41, 3173–3182 (2010). https://doi.org/10.1007/s11661-010-0399-8

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