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Intermetallic Diminution During Friction Stir Welding of Dissimilar Al/Mg Alloys in Lap Configuration Via Ultrasonic Assistance

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Abstract

This study shows the influence of ultrasonic vibrations on the nature and thickness of intermetallic compounds (IMCs) and the correlation with the weld shear load. An ultrasonic vibration assembly comprised of novel horn attachments and a special welding tool has been developed to impart a thermomechanical-acoustic effect on the stirred zone (SZ). The IMC analysis is made at the SZ and interfaces to portray a complete scenario of their formation mechanism. The outcomes depict a complete elimination of harmful IMC phase Al3Mg2 (β) and the shrinkage of Al12Mg17 (γ) at acoustically treated regions under the optimum parameters. The aforesaid evidence is further supported by elemental mapping, energy-dispersive X-ray spectrometry, and diffraction pattern analysis. With ultrasonic assistance, a maximum reduction in IMC layer thickness up to 56.5 pct has been achieved. The weld shear load and joint efficiency are increased by 26.1 and 26.1 pct, respectively, during the ultrasonic addition. The acoustic assistance helps diminish the IMC thickness, while the morphology and mechanism of their formation remain the same.

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ACKNOWLEDGMENT

The authors acknowledge the financial support from the Key R&D Program of Shandong Province in China (Grant No. 2018GGX103001).

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  1. MOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University, Jinan, 250061, China

    Sachin Kumar, Chuansong Wu & Lei Shi

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  1. Sachin Kumar
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Correspondence to Chuansong Wu.

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Manuscript submitted on May 26, 2020.

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Kumar, S., Wu, C. & Shi, L. Intermetallic Diminution During Friction Stir Welding of Dissimilar Al/Mg Alloys in Lap Configuration Via Ultrasonic Assistance. Metall Mater Trans A 51, 5725–5742 (2020). https://doi.org/10.1007/s11661-020-05982-z

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