Thermal process and material flow during dissimilar double-sided friction stir spot welding of AZ31/ZK60 magnesium alloys

Ke, Wenchao; Oliveira, J.P.; Ao, Sansan; Teshome, Fissha Biruke; Chen, L.; Peng, Bei; Zeng, Zhi

doi:10.1016/j.jmrt.2022.01.097

Cited by 52 publications

(17 citation statements)

References 42 publications

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“…Mg alloys have decent properties, such as specific strength, sound-damping ability, formability, and reusability [ 8 ]. On the other hand, Mg has less hardness, strength, fatigue, stiffness, [ 9 ] creep, and corrosion-resistance properties at room temperature due to the HCP crystal structure [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Joining of Dissimilar Al and Mg Metal Alloys by Friction Stir Welding

Sidhu

Kumar

Goel³

et al. 2022

Materials

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In engineering applications, such as automobile, marine, aerospace, and railway, lightweight alloys of aluminum (Al) and magnesium (Mg) ensure design fitness for fuel economy, better efficiency, and overall cost reduction. Friction stir welding (FSW) for joining dissimilar materials has been considered better than the conventional fusion welding process because of metallurgical concerns. In this study, dissimilar joints were made between the AA6061 (A), AZ31B (B), and AZ91D (C) combinations based on the varying advancing side (AS) and retreating side (RS). The dissimilar joints prepared by the FSW process were further characterized by tensile testing, impact testing, corrosion testing, fracture, and statistical and cost analysis. The results revealed a maximum tensile strength of 192.39 MPa in AZ91 and AZ31B, maximum yield strength of 134.38 MPa in a combination of AA6061 and AZ91, maximum hardness of 114 Hv in AA6061 and AZ31B, and lowest corrosion rate of 7.03 mV/A in AA6061 and AZ31B. The results of the properties were supported by photomicrographic fracture analysis by scanning electron microscopy (SEM) observations. Further, the performance of dissimilar joints was statistically analyzed and prioritized for preference by similarity to the ideal solution (TOPSIS) method.

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Section: Introductionmentioning

confidence: 99%

Joining of Dissimilar Al and Mg Metal Alloys by Friction Stir Welding

Sidhu

Kumar

Goel³

et al. 2022

Materials

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“…Successful joints were made of polymers such as Polyethylene (PE) [ 53 , 54 ], Polycarbonate (PC) [ 55 , 56 ], and Polymethyl Methacrylate (PMMA) [ 57 , 58 ]. Furthermore, the FSW process was utilized to join dissimilar metals [ 59 , 60 , 61 , 62 , 63 , 64 , 65 , 66 , 67 , 68 ], dissimilar polymers [ 69 , 70 , 71 ], and hybrid metal–polymer joints [ 72 , 73 , 74 , 75 , 76 , 77 , 78 , 79 , 80 , 81 , 82 , 83 , 84 , 85 , 86 , 87 , 88 ]. Therefore, the FSW process gained global recognition due to its potential in various applications in the automotive, aerospace, shipbuilding, and railway industries [ 89 ].…”

Section: Introductionmentioning

confidence: 99%

“…It was concluded that increasing the tilt angle in the range of 0–2°, while setting the plunge depth variation in the range of 0.1–0.4 mm, results in an optimum effect [ 88 ]. Ke et al studied the thermal process of friction stir spot welding of dissimilar metals and provided a computational fluid dynamics model simulating the material flow throughout the process stages [ 65 ].…”

Section: Introductionmentioning

confidence: 99%

A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures

et al. 2022

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Metal–polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal–polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal–polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal–polymer joint quality that have been reported in the literature.

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“…In order to obtain a high-quality magnesium alloy welded joint, reliable and effective welding technologies have been developed for magnesium alloys in recent years [ 4 , 5 ]. The developed welding methods include laser welding [ 6 ], friction stir welding [ 7 ], and laser–tungsten inert gas hybrid welding [ 8 ].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experimental Study on the TIG (A-TIG) Welding of Dissimilar Magnesium Alloys

Qin

Xie

et al. 2022

Materials

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The welding experiments and numerical simulation analysis of dissimilar magnesium alloy AZ61-AM60 were carried out by TIG and A-TIG methods. The mathematical model of welding pool under three-dimensional transient moving heat source has been established, and the temperature field has been numerically simulated. The influence of welding process parameters on the surface forming quality of welded joints has been discussed. The simulation results show that temperature field distribution of dissimilar magnesium alloy AZ61-AM60 during the TIG welding process presents a certain asymmetry and the shape distribution of the melting field on both sides of the molten pool is asymmetrical. When A-TIG welding was coated with activating flux, the surface of the molten pool is ingot-shaped. These simulation results are verified through experiment investigation. The consistency between the experimental results and the simulation results reveals the variation law of temperature field and molten pool shape in the welding process, which provides an effective guidance for the optimization of welding process parameters of dissimilar magnesium alloys.

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Thermal process and material flow during dissimilar double-sided friction stir spot welding of AZ31/ZK60 magnesium alloys

Cited by 52 publications

References 42 publications

Joining of Dissimilar Al and Mg Metal Alloys by Friction Stir Welding

Joining of Dissimilar Al and Mg Metal Alloys by Friction Stir Welding

A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures

Numerical Simulation and Experimental Study on the TIG (A-TIG) Welding of Dissimilar Magnesium Alloys

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