Abstract
In the past two decades, there has been an ever-increasing demand for solid-state welding of dissimilar materials. This type of solid-state welding technique is gaining prominence in various disciplines but more importantly in naval, marine, aerospace and military applications. Most of the leading car manufactures today are exploring the possibilities of joining magnesium with aluminium, via solid-state welding process. In the present scenario these techniques are applicable for automotive applications like transmission cases and oil pans. In this work, the different types of solid-state welding techniques that were used for joining of aluminium alloys with magnesium alloys are reviewed from different perceptions. One of the important issues that is faced during joining of these dissimilar materials, is the formation of intermetallic compounds (IMCs) at the welded interface. The work also highlights the influence of various process parameters, structural morphology, intermetallic compound formation and variations in mechanical properties. Some of the important Solid-state welding processes that are elucidated here includes: friction welding, friction stir welding, friction stir spot welding, diffusion welding and third body welding. The above said techniques are carefully analysed for the formation of a satisfactory and quality sound aluminium-magnesium joints. In the overview, it can be summarized that friction-based joining processes have great potential to obtain sound Al–Mg joints. The amount of frictional heat generated at the surface of the contact helps to decide the type and volume fraction of IMCs that are subsequently affecting the mechanical properties of the joints. The joint properties can be enhanced by optimizing the process parameters.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Cam, G., Kocak, M.: Progress in joining of advanced materials. Int. Mater. Rev. 43, 1–44 (1998)
Lanza, M., Lauro, A., Scanavino, S.: Fabrication and weldability in structures. AL Alumin. Alloys 13, 80–86 (2001)
Meshram, S.D., Mohandas, T., Madhusudhan Reddy, G.: Friction welding of dissimilar pure metals. J. Mater. Process. Technol. 184, 330–337 (2007)
Rajesh, N., et al.: Mechanical evaluation and microstructure of friction welded aluminium-mild steel joints. Arab. J. Sci. Eng. 39, 5017–5023 (2014)
Mishra, A.: Friction stir welding of dissimilar metal: a review. Int. J. Res. Appl. Sci. Eng. Technol. 6(I), 1551–1559 (2018)
Liu, Liming, Ren, Daxin, Liu, Fei: A review of dissimilar welding techniques for magnesium alloys to aluminum alloys. Materials (Basel) 7(5), 3735–3757 (2014)
Sassani, F., Neelam, J.R.: Friction Welding of Incompatible Materials, 264-s I, Nov 1988
Giummarra, C., Thomas, B., Rioja, R.J.: New aluminum lithium alloys for aerospace applications. In: Proceedings of the Light Metals Technology Conference (2007)
Rajesh, et al.: Investigation on joining of aluminum & mild steel by friction stud welding. Mater. Manuf. Process 27, 1409–1413
Blawert, C., Hort, N., Kainer, K.U.: Automotive applications of magnesium and its alloys. Institute for Materials Research, 10 May 2004
Mordike, B.L., Ebert, T.: Magnesium: properties—applications—potential. Mater. Sci. Eng. A 302, 37–45 (2001)
Borrisutthekul, R., Miyashita, Y., Mutoh, Y.: Dissimilar material laser welding between magnesium alloy MgAZ31B and aluminum alloy A5052-O. Sci. Technol. Adv. Mater. 6, 199–204 (2005)
Liu, P., Li, Y., Wang, J., Haijun, M.A., Guo, G., Geng, H.: Microstructure and phase constituents in the interface zone of Mg/Al diffusion bonding. Metall. Mater. Trans. B 37, 649–654 (2006)
Cao, R., Wen, B.F., Chen, J.H., Wang, P.C.: Cold metal transfer joining of magnesium MgAZ31B-to-aluminum A6061-T6. Mater. Sci. Eng. A 560, 256–266 (2013)
Liang, Z., Qin, G., Wang, L., Meng, X., Li, F.: Microstructural characterization and mechanical properties of dissimilar friction welding of 1060 aluminum to MgAZ31B magnesium alloy. Mater. Sci. Eng. A 645, 170–180 (2015)
Kimura, M., Fuji, A., Shibata, S.: Joint properties of friction welded joint between pure magnesium and pure aluminium with post weld heat treatment. Mater. Des. 85, 169–179 (2015)
Paradiso, V., Rubino, F., Carlone, P., Palazzo, G.S.: Magnesium and aluminium alloys dissimilar joining by friction stir welding. Procedia Eng. 183, 239–244 (2017)
Su, J.Q., Nelson, T.W., Mishra, R., Mahoney, M.: Microstructural investigation of friction stir welded 7050-T651 aluminium. Acta Mater. 51, 713–729 (2003)
Hirano, S., Okamoto, K., Doi, M., Okamura, H., Inagaki, M., Aono, Y.: Microstructure of dissimilar joint interface of magnesium alloy and aluminum alloy by friction stir welding. Q. J. Jpn. Weld. Soc. 21, 539 (2003)
Park, S.H.C., Michiuchi, M., Sato, Y.S., Kokawa, H.: Dissimilar friction-stir welding of Al alloy 1050 and Mg alloy AZ31. In: Proceedings of the International Welding/Joining Conference-Korea, Gyeongju, Korea, pp. 534–538, 28–30 Oct 2002
Yan, Y., Zhang, D.T., Qiu, C., Zhang, W.: Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy. Trans. Nonferrous Met. Soc. China 20, S619–S623 (2010)
Somasekharan, A.C., Murr, L.E.: Microstructures in friction-stir welded dissimilar magnesium alloys and magnesium alloys to 6061-T6 aluminum alloy. Mater. Charact. 52, 49–64 (2004)
Straumal, B.B., Baretzky, B., Kogtenkova, O.A., Straumal, A.B., Sidorenko, A.S.: Wetting of grain boundaries in Al by the solid Al3Mg2 phase. J. Mater. Sci. 45, 2057–2061 (2010)
Protasova, S.G., Kogtenkova, O.A., Straumal, B.B., Zieba, P., Baretzky, B.: Inversed solid-phase grain boundary wetting in the Al–Zn system. J. Mater. Sci. 46, 4349–4353 (2011)
Gerlich, A., Su, P., Yamamoto, M., North, T.H.: Material flow and intermixing during dissimilar friction stir welding. Sci. Technol. Weld. Join. 13, 254–264 (2008)
Mahoney, M.W., Rhodes, C.G., Flintoff, J.G., Bingel, W.H., Spurling, R.A.: Properties of friction-stir-welded 7075 T651 aluminum. Metall. Mater. Trans. A 29, 1955–1964 (1997)
Guerra, M., Schmidt, C., McClure, J.C., Murr, L.E., Nunes, A.C.: Flow patterns during friction stir welding. Mater. Charact. 49, 95–101 (2003)
Suni, B.R., Reddy, G.P.K., Mounika, A.S.N., Sree, P.N., Pinneswari, P.R.: Joining of AZ31 and AZ91 Mg alloys by friction stir welding. J. Magnes. Alloys 3, 330–334 (2015)
Jaiganesh, V., Sevvel, P.: Effect of process parameters on the microstructural characteristics and mechanical properties of AZ80AMg alloy during friction stir welding. Trans. Indian Inst. Met. 68, 99–104 (2015)
Rose, A.R., Manisekar, K., Balasubramanian, V.: Influences of welding speed on tensile properties of friction stir welded AZ61A magnesium alloy. J. Mater. Eng. Perform. 21, 257–265 (2012)
Kouadri-Henni, A., Barrallier, L.: Mechanical properties, microstructure and crystallographic texture of magnesium AZ91-D alloy welded by friction stir welding (FSW). Metall. Mater. Trans. A 45, 4983–4996 (2014)
Mofid, M.A., Abdollah-Zadeh, A., Malek Ghaini, F.: The effect of water cooling during dissimilar friction stir welding of Al alloy to Mg alloy. Mater. Des. 36, 161–167 (2012)
Cooke, K.O., Alhazaa, A., Atieh, A.M.: Dissimilar Welding and Joining of Magnesium Alloys: Principles and Application. Intech Open. http://dx.doi.org/10.5772/intechopen.85111, 23 Apr 2019
Singh, K., Singh, G., Singh, H.: Review on friction stir welding of magnesium alloys. J. Magnes. Alloys (2018)
Venkateswaran, P., Reynolds, A.P.: Factors affecting the properties of friction stir welds between aluminum and magnesium alloys. Mater. Sci. Eng. A 545, 26–37 (2012)
Elanchezhian, C., Ramnath, B.V., Venkatesan, P., Sathish, S., Vignesh, T., Siddharth, R.V., Gopinath, K.: Procedia Eng. 97, 775–782 (2014)
Chen, Y.C., Nakata, K.: Friction stir lap joining aluminum and magnesium alloys. Scr. Mater. 58, 433–436 (2008)
Chowdhury, S.H., Chen, D.L., Bhole, S.D., Cao, X., Wanjara, P.: Lap shear strength and fatigue life of friction stir spot welded AZ31 magnesium and 5754 aluminum alloys. Mater. Sci. Eng. A 556, 500–509 (2012)
Kwon, Y.J., Shigematsu, I., Saito, N.: Dissimilar friction stir welding between magnesium and aluminum alloys. Mater. Lett. 62, 3827–3829 (2008)
Kouadri-Henni, A., Barrallier, L.: Mechanical properties, microstructure and crystallographic texture of magnesium AZ91-D alloy welded by friction stir welding (FSW). Metall. Mater. Trans. A 45, 4983–4996 (2014)
Esparza, J.A., Davis, W.C., Trillo, E.A., Murr, L.E.: J. Mater. Sci. Lett. 21(12), 917–920 (2002)
Lim, S., Kim, S., Lee, C.G., Kim, S.J., Yim, C.D.: Metall. Mater. Trans. A 36(6), 1609–1612 (2005)
Lee, W.B., Yeon, Y.M., Jung, S.B.: Mater. Sci. Technol. 19(6), 785–790 (2003)
Padmanaban, G., Balasubramanian, V.: Mater. Des. 30(7), 2647–2656 (2009)
Chowdhury, S.H., Chen, D.L., Bhole, S.D., Cao, X., Wanjara, P.: Metall. Mater. Trans. A 44(1), 323–336 (2013)
Choi, D.H., Ahn, B.W., Kim, S.K., Yeon, Y.M., Kim, Y.J., Park, S.K., Jung, S.B.: Mater. Trans. 52(4), 802–805 (2011)
Singarapu, U., Adepu, K., Arumalle, S.R., Magnes, J.: Alloys 3(4), 335–344 (2015)
Liu, L.M., Tan, J.H., Liu, X.J.: Reactive brazing of Al alloy to Mg alloy using zinc-based brazing alloy. Mater. Lett. 61, 2373–2377 (2007)
Zhao, L.M., Zhang, Z.D.: Effect of Zn alloy interlayer on interface microstructure and strength of diffusion-bonded Mg-Al joints. Scr. Mater. 58, 283–286 (2008)
Liu, L.M., Zhao, L.M., Xu, R.Z.: Effect of interlayer composition on the microstructure and strength of diffusion bonded Mg/Al joint. Mater. Des. 30, 4548–4551 (2009)
Zhang, H.T., Song, J.Q.: Microstructural evolution of aluminum magnesium lap joints welded using MIG process with zinc foil as an interlayer. Mater. Lett. 65, 3292–3294 (2011)
Scherm, F., Bezold, J., Glatzel, U.: Laser welding of Mg alloy MgAl3Zn1 (AZ31) to Al alloy AlMg3 (AA5754) using ZnAl filler material. Sci. Technol. Weld. Join. 17, 364–367 (2012)
Liu, F., Zhang, Z.D., Liu, L.M.: Microstructure evolution of Al/Mg butt joints welded by gas tungsten arc with Zn filler metal. Mater. Charact. 69, 84–89 (2012)
Şahin, M.: Friction welding of different materials. In: International Scientific Conference, Gabrovo, 19–20 Nov 2010
Liang, Z., Qin, G., Geng, P., Yang, F., Meng, X.: Continuous drive friction welding of 5A33 Al alloy to MgAZ31B alloy. J. Manuf. Process. 25, 153–162 (2017)
Liu, F., Ren, D.X., Liu, L.M.: Effect of Al foils interlayer on microstructures and mechanical properties of Mg-Al butt joints welded by gas tungsten arc welding filling with Zn filler metal. Mater. Des. 46, 419–425 (2013)
Automotive Uses of Magnesium Alloys: Part One, Total Materia, July 2010
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Switzerland AG
About this chapter
Cite this chapter
Shenbaga Velu, P., Vignesh, N.J., Rajesh Jesudoss Hynes, N. (2020). Surface Characteristics When Solid State Welding of Aluminium Alloys to Magnesium Alloys. In: Gupta, K. (eds) Surface Engineering of Modern Materials. Engineering Materials. Springer, Cham. https://doi.org/10.1007/978-3-030-43232-4_4
Download citation
DOI: https://doi.org/10.1007/978-3-030-43232-4_4
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-43231-7
Online ISBN: 978-3-030-43232-4
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)