AA2519-T87 aluminium alloy is newly developed armour grade, age hardenable alloy with best mechanical properties, high impact toughness and ballistic resistance properties Because of this beneficial property it is preferable in replacement of steels in the light combat vehicles in order to reduce the weight and improves mobility. Formation of oxide layers, solidification cracking and porosity creates problems in the fusion welding of aluminium alloys. Gas tungsten arc welding (GTAW) is widely used fusion welding process for joining aluminium alloys which results improved arc stability, reduced thermal distortion, reduced residual stress and spatter free joints. By proper controlling of process parameters of GTAW, sound weld joint is achieved at welding current of 145 A, welding speed of 2 mm/s, and voltage of 16 V. Due to heating and rapid cooling cycles, the weld joints properties deteriorated due to loss of
Active soldering is an emerging technology of joining a range of materials, which utilizes Sn-Ag composition solder alloy other than conventional Sn-Pb solder, along with reactive element additions (like Ti, Ta, Hf and Zr). In the present study, active soldering is employed for bonding AA6061 aluminium alloy using S Bond 220-50 and S Bond 220M active solders. Soldering was achieved by direct active soldering of AA6061 plates each other using S Bond 220-50 and PEO coated AA6061 aluminium alloy using S Bond 220M, taking into consideration of the application of active solder alloy in joining ceramics. Mechanical properties were evaluated using hardness and lap shear test. Microstructure analysis is carried out by SEM microscopy. The soldered area is examined using EDS giving fair idea regarding the composition of elements present in the solder. It is observed that direct bonding of aluminium alloy using S Bond 220-50 showed better bond strength and hardness when compared with joining using S Bond 220M of the PEO coated aluminium plate.
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