Research Progress in Dissimilar Friction Stir Welding of Aluminium/Magnesium Alloys

doi:10.3901/JME.2020.06.004

Abstract

Abstract: With the increasing demand for environmental protection, energy saving and emission reduction, the lightweight structures of aluminum alloys and magnesium alloys are increasingly used in industries such as aerospace, high-speed trains, automobiles, and new energy fields. Particularly, the joining of aluminum-magnesium dissimilar alloys faces many challenges and is one of the key technical issue that needs to be solved urgently. Compared with other joining methods, friction stir welding(FSW) shows a great advantage in joining aluminum-magnesium dissimilar metals. In recent years, some new FSW variant processes have emerged. According to the research progress in the field of aluminum-magnesium dissimilar alloys FSW in recent years, this paper comprehensively reviews the research status, existing problems and the important unsolved issues in this field. The purpose is to clarify the physical mechanism, technical difficulties and solutions of FSW and its modification processes in joining of dissimilar aluminum-magnesium alloys, and promote the wide application of aluminum-magnesium hybrid-structure in the automotive industry.

Key words: aluminum alloys, magnesium alloys, dissimilar joints, friction stir welding

CLC Number:

TG402

WU Chuansong, Lü Xueqi, SU Hao, SHI Lei. Research Progress in Dissimilar Friction Stir Welding of Aluminium/Magnesium Alloys[J]. Journal of Mechanical Engineering, 2020, 56(6): 4-16.

References

[1] DEBBARMA S,KAUSHIK G. Assessing the impact of transportation on climate Change:A case study of Agartala City in India's north east region//Handbook of Research on Environmental Policies for Emergency Management and Public Safety[M]. IGI Global,2018:275-299.
[2] 李永兵,马运五,楼铭,等.轻量化多材料汽车车身连接技术进展[J].机械工程学报,2016,52(24):1-23. LI Yongbing,MA Yunwu,LOU Ming,et al. Advances in welding and joining processes of multi-material lightweight car body[J]. Journal of Mechanical Engineering,2016,52(24):1-23.
[3] 黄文森,童德祥,蔡月华,等.铝合金型材在汽车轻量化中的应用[C/CD]//LW2016第六届铝加工技术(国际)论坛,杭州,2016. HUANG Wensen,TONG Dexiang,CAI Yuehua,et al. Application of aluminum alloy extrusions in lightweight of automobile[C/CD]//LW2016,Hangzhou,2016.
[4] 刘静安,刘煜.铝材在汽车上的开发应用及重点新材料产品研发方向[C/CD]//LW2013第五届铝型材技术(国际)论坛,广州,2013. LIU Jingan,LIU Yu. Development and application of aluminum alloy extrusions in automobile and research direction of key new materials products[C/CD]//LW2013,Guangzhou,2013.
[5] 陈军.镁合金在汽车工业中的应用分析[J].材料研究与应用,2010(2):81-84. CHEN Jun. Application analysis of magnesium alloy in automotive industry[J]. Materials Research and Application,2010(2):81-84.
[6] LUO A A. Magnesium casting technology for structural applications[J]. Journal of Magnesium and Alloys,2013,1(1):2-22.
[7] SHAH L H,OTHMAN N H,GERLICH A. Review of research progress on aluminum-magnesium dissimilar friction stir welding[J]. Science and Technology of Welding and Joining,2018,23:256-270.
[8] 马宗义,商乔,倪丁瑞,等.镁合金搅拌摩擦焊接的研究现状与展望[J].金属学报,2018,54(11):1594-1617. MA Zongyi,SHANG Qiao,NI Dingrui,et al. Friction stir welding of magnesium alloy:A review[J]. Acta Metallurgica Sinica,2018,54(11):1594-1617.
[9] 王志,刘飞,刘黎明.钎焊温度及保温时间对Sn-30Zn钎料钎焊Mg/Al异种金属组织和性能的影响[J].焊接学报,2012,33(10):79-82. WANG Zhi,LIU Fei,LIU Liming. Effect of brazing temperature and holding time on microstructure and strength of brazed joints between dissimilar materials Mg/Al[J]. Transactions of the China Welding Institution,2012,33(10):79-82.
[10] LIU L,TAN J,LIU X. Reactive brazing of Al alloy to Mg alloy using zinc-based brazing alloy[J]. Materials Letters,2007,61(11-12):2373-2377.
[11] MAHENDRAN G,BALASUBRAMANIAN V,SENTHILVELAN T. Developing diffusion bonding windows for joining AZ31B magnesium-AA2024 aluminium alloys[J]. Materials & Design,2009,30(4):1240-1244.
[12] MAHENDRAN G,BABU S,BALASUBRAMANIAN V. Analyzing the effect of diffusion bonding process parameters on bond characteristics of Mg-Al dissimilar joints[J]. Journal of Materials Engineering and Performance,2010,19(5):657-665.
[13] PATEL V K,BHOLE S D,CHEN D L. Microstructure and mechanical properties of dissimilar welded Mg-Al joints by ultrasonic spot welding technique[J]. Science and Technology of Welding and Joining,2013,17(3):202-206.
[14] BORRISUTTEKUL R,MIYASHITA Y,MUTOH Y. Dissimilar material laser welding between magnesium alloy AZ31B and aluminum alloy A5052-O[J]. Science and Technology of Advanced Materials,2005,6(2):199-204.
[15] LIU L M,WANG H Y,ZHANG Z D. The analysis of laser weld bonding of Al alloy to Mg alloy[J]. Scripta Materialia,2007,56(6):473-476.
[16] 孙梦.基于中间层的AZ31镁合金/5052铝合金电阻点焊焊接性研究[D].哈尔滨:哈尔滨工业大学,2016. SUN Meng. Study on the resistance spot weldability of AZ31 magnesium alloy to 5052 aluminum alloy with different interlayers[D]. Harbin:Harbin Institute of Technology,2016.
[17] LIU F,ZHANG Z,LIU L. Microstructure evolution of Al/Mg butt joints welded by gas tungsten arc with Zn filler metal[J]. Materials Characterization,2012,69:84-89.
[18] ZHANG H T,SONG J Q. Microstructural evolution of aluminum/magnesium lap joints welded using MIG process with zinc foil as an interlayer[J]. Materials Letters,2011,65(21-22):3292-3294.
[19] 王克鸿,朱功杰,余进.铝合金与镁合金直流双脉冲MIG焊接头组织与性能研究[J].机械制造与自动化,2017(1):29-31. WANG Kehong,ZHU Gongjie,YU Jin. Study of mechanical properties and structure of Al-Mg dissimilar welding joint with DC double pulse MIG[J]. Mechanical Manufacturing and Automation,2017(1):29-31.
[20] MCLEAN A A,POWELL G L F,BROWN I H,et al. Friction stir welding of magnesium alloy AZ31B to aluminium alloy 5083[J]. Science and Technology of Welding and Joining,2013,8(6):462-464.
[21] FIROUZDOR V,KOU S. Al-to-Mg friction stir welding:effect of material position,travel speed,and rotation speed[J]. Metallurgical and Materials Transactions A,2010,41(11):2914-2935.
[22] FIROUZDOR V,KOU S. Formation of liquid and intermetallics in Al-to-Mg friction stir welding[J]. Metallurgical and Materials Transactions A,2010,41:3238-3250.
[23] YAN J,XU Z,LI Z,et al. Microstructure characteristics and performance of dissimilar welds between magnesium alloy and aluminum formed by friction stirring[J]. Scripta Materialia,2005,53(5):585-589.
[24] YAMAMOTO N,LIAO J,WATANABE S,et al. Effect of intermetallic compound layer on tensile strength of dissimilar friction-stir weld of a high strength Mg alloy and Al alloy[J]. Materials Transactions,2009,50(12):2833-2838.
[25] 康举,付瑞东,栾国红,等.搅拌针偏移对7075铝合金-AZ31镁合金接头组织及性能的影响[J].稀有金属材料与工程,2011(S2):294-299. KANG Ju,FU Ruidong,LUAN Guohong,et al. Effect of the pin offsetting on microstructures and mechanical properties of FSW joints of 7075 Al alloy-AZ31B Mg alloy[J]. Rare Metal Materials and Engineering,2011(S2):294-299.
[26] MALAVIZHI S,BALASUBRAMANIAN V. Influences of tool shoulder diameter to plate thickness ratio (D/T) on stir zone formation and tensile properties of friction stir welded dissimilar joints of AA6061 aluminum-AZ31B magnesium alloys[J]. Materials & Design,2012,40:453-460.
[27] MORISHIGE T,KAWAGUCHI A,TSUJIKAWA M,et al. Dissimilar welding of Al and Mg alloys by FSW[J]. Materials Transactions,2008,9(5):1129-1131.
[28] SIMONCINI M,FORCELLESE A. Effect of the welding parameters and tool configuration on micro-and macro-mechanical properties of similar and dissimilar FSWed joints in AA5754 and AZ31 thin sheets[J]. Materials & Design,2012,41:50-60.
[29] KWON Y J,SHIGEMATSU I,SAITO N. Dissimilar friction stir welding between magnesium and aluminum alloys[J]. Materials Letters,2008,62(23):3827-3829.
[30] KHODIR S A,SHIBAYANAGI T. Dissimilar friction stir welded joints between 2024-T3 aluminum alloy and AZ31 magnesium alloy[J]. Materials Transactions,2007,48(9):2501-2505.
[31] DORBANE A,MANSOOR B,AYOUB G,et al. Mechanical,microstructural and fracture properties of dissimilar welds produced by friction stir welding of AZ31B and Al6061[J]. Materials Science and Engineering:A,2016,651:720-733.
[32] ZETTLER R,DA SILVA A A M,RODRIGUES S,et al. Dissimilar Al to Mg alloy friction stir welds[J]. Advanced Engineering Materials,2006,8(5):415-421.
[33] SOMASEKHARAN A C,MURR L E. Microstructures in friction-stir welded dissimilar magnesium alloys and magnesium alloys to 6061-T6 aluminum alloy[J]. Materials Characterization,2004,52(1):49-64.
[34] XUE P,XIAO B L,WANG D,et al. Achieving high property friction stir welded aluminium/copper lap joint at low heat input[J]. Science and Technology of Welding and Joining,2011,16(8):657-661.
[35] VENKATESWARAN P,REYNOLDS A P. Factors affecting the properties of friction stir welds between aluminum and magnesium alloys[J]. Materials Science and Engineering:A,2012,545:26-37.
[36] SATO Y S,PARK S H C,MICHIUCHI M,et al. Constitutional liquation during dissimilar friction stir welding of Al and Mg alloys[J]. Scripta Materialia,2004,50(9):1233-1236.
[37] ZHANG H,CHEN Y,LUO A A. A novel aluminum surface treatment for improved bonding in magnesium/aluminum bimetallic castings[J]. Scripta Materialia,2014,86:52-55.
[38] SUHUDDIN U F H,FISCHER V,DOS SANTOS J F. The thermal cycle during the dissimilar friction spot welding of aluminum and magnesium alloy[J]. Scripta Materialia,2013,68(1):87-90.
[39] KLAG O,GROEBNER J,WAGNER G,et al. Microstructure and thermodynamic investigations on friction stir welded Mg/Al-joints[J]. International Journal of Materials Research,2014,105(2):145-155.
[40] FU B,QIN G,LI F,et al. Friction stir welding process of dissimilar metals of 6061-T6 aluminum alloy to AZ31B magnesium alloy[J]. Journal of Materials Processing Technology,2015,218:38-47.
[41] LIANG Z,CHEN K,WANG X,et al. Effect of tool offset and tool rotational speed on enhancing mechanical property of Al/Mg dissimilar FSW joints[J]. Metallurgical and Materials Transactions A,2013,44:3721-3731.
[42] SHI H,CHEN K,LIANG Z,et al. Intermetallic compounds in the banded structure and their effect on mechanical properties of Al/Mg dissimilar friction stir welding joints[J]. Journal of Materials Science & Technology,2017,33(4):359-366.
[43] MOFID M A,ABDOLLAH-ZADEH A,GHAINI F M,et al. Submerged friction-stir welding (SFSW) underwater and under liquid nitrogen:an improved method to join Al alloys to Mg alloys[J]. Metallurgical and Materials Transactions A,2012,43(13):5106-5114.
[44] MOFID M A,ABDOLLAH-ZADEH A,GUR C H. Investigating the formation of intermetallic compounds during friction stir welding of magnesium alloy to aluminum alloy in air and under liquid nitrogen[J]. The International Journal of Advanced Manufacturing Technology,2014,71(5-8):1493-1499.
[45] ZHAO Y,LU Z,YAN K,et al. Microstructural characterizations and mechanical properties in underwater friction stir welding of aluminum and magnesium dissimilar alloys[J]. Materials & Design,2015,65:675-681.
[46] ZHAO Y,JIANG S,YANG S,et al. Influence of cooling conditions on joint properties and microstructures of aluminum and magnesium dissimilar alloys by friction stir welding[J]. The International Journal of Advanced Manufacturing Technology,2016,83(1-4):673-679.
[47] CHANG W,RAJESH S R,CHUN C,et al. Microstructure and mechanical properties of hybrid laser-friction stir welding between AA6061-T6 Al alloy and AZ31 Mg alloy[J]. Journal of Materials Science and Technology,2011,27(3):199-204.
[48] DAUD Y,LUCAS M,HUANG Z. Modelling the effects of superimposed ultrasonic vibrations on tension and compression tests of aluminium[J]. Journal of Materials Processing Technology,2007,186(1-3):179-190.
[49] 武传松,刘小超,张皓庭.超声振动辅助搅拌摩擦焊工艺及装置:ZL201210244175.8[P]. 2013-02-13. WU Chuansong,LIU Xiaochao,ZHANG Haoting. Process and installation of ultrasonic vibration enhanced friction stir welding:ZL201210244175.8[P]. 2013-02-13.
[50] LIU X C,WU C S,PADHY G K. Improved weld macrosection,microstructure and mechanical properties of 2024-T4 butt joints in ultrasonic vibration enhanced friction stir welding[J]. Science and Technology of Welding and Joining,2015,20(4):345-352.
[51] ZHONG Y B,WU C S,PADHY G K. Effect of ultrasonic vibration on welding load,temperature and material flow in friction stir welding[J]. Journal of Materials Processing Technology,2017,239:273-283.
[52] 吕学奇,杨春靓,武传松.铝-镁合金的超声振动强化搅拌摩擦焊试验研究[J].机械工程学报,2016,52(24):58-64. LÜ Xueqi,YANG Chunliang,WU Chuansong. Experimental investigation on ultrasonic vibration enhanced FSW of Al-Mg dissimilar materials[J]. Journal of Mechanical Engineering,2016,52(24):58-64.
[53] LV X Q,WU C S,PADHY G K. Weld microstructure and mechanical properties in ultrasonic enhanced friction stir welding of Al alloy to Mg alloy[J]. Journal of Materials Processing Technology,2018,254:145-157.
[54] LV X Q,WU C S,PADHY G K. Diminishing intermetallic compound layer in ultrasonic vibration enhanced friction stir welding of aluminum alloy to magnesium alloy[J]. Materials Letters,2017,230:81-84.
[55] 吕学奇.超声振动对Al/Mg异种合金搅拌摩擦焊接接头组织与性能的影响[D].济南:山东大学,2018. LÜ Xueqi. Study on the resistance spot weldability of AZ31 magnesium alloy to 5052 aluminum alloy with different interlayers[D]. Jinan:Shandong University,2018.
[56] JI S D,LI Z W,MA L,et al. Investigation of ultrasonic assisted friction stir spot welding of magnesium alloy to aluminum alloy[J]. Strength of Materials,2016,48(1):2-7.
[57] JI S,MENG X,LIU Z,et al. Dissimilar friction stir welding of 6061 aluminum alloy and AZ31 magnesium alloy assisted with ultrasonic[J]. Materials Letters,2017,201:173-176.
[58] JI S,HUANG R,MENG X,et al. Enhancing friction stir weldability of 6061-T6 Al and AZ31B Mg alloys assisted by external non-rotational shoulder[J]. Journal of Materials Engineering and Performance,2017,26(5):2359-2367.
[59] LIU Z,MENG X,JI S,et al. Improving tensile properties of Al/Mg joint by smashing intermetallic compounds via ultrasonic-assisted stationary shoulder friction stir welding[J]. Journal of Manufacturing Processes,2018,31:552-559.
[60] STRASS B,WAGNER G,EIFLER D. Realization of Al/Mg-hybrid-joints by ultrasound supported friction stir welding[J]. Materials Science Forum,2014,783-786:1814-1819.
[61] STRASS B,WAGNER G,CONRAD C,et al. Realization of Al/Mg-hybrid-joints by ultrasound supported friction stir welding-mechanical properties,microstructure and corrosion behavior[J]. Advanced Materials Research,2014,966-967:521-535.
[62] BENFER S,STRASS B,WAGNER G,et al. Manufacturing and corrosion properties of ultrasound supported friction stir welded Al/Mg-hybrid joints[J]. Surface and Interface Analysis,2016,48(8):843-852.
[63] THOMA M,WAGNER G,STRASS B,et al. Recent developments for ultrasonic-assisted friction stir welding:Joining,testing,corrosion:An overview[J]. IOP Conference Series:Materials Science and Engineering,2016,118:12014.