Process Parametric Dependency of Axial Downward Force and Macro- and Microstructural Morphologies in Ultrasonically Assi
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ALUMINUM (Al) and magnesium (Mg) alloys have been extensively used to manufacture various structural components for numerous applications.[1] In order to enable their full-fledge applications, a successful joining of both metals is vital. Therefore, the dissimilar joining of Al and Mg alloys has become a crucial technological problem and attracted major research attention across the globe.[2] Various fusion welding techniques have been attempted to obtain sound joints of Al and Mg alloys. Unfortunately, most of them could not get widespread consent due to the frequent formation of various weld defects.[3] Besides, the massive formation of brittle intermetallic compounds (IMC) in the weld zone has further degraded the joint strength.[4] During metal inert gas welding of 1060Al/AZ31Mg, Wang et al.[5] have
SACHIN KUMAR, CHUANSONG WU, and SONG GAO are with the MOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University Jinan, 250061 P.R. China. Contact e-mail: [email protected] Manuscript submitted April 1, 2019.
METALLURGICAL AND MATERIALS TRANSACTIONS A
reported the IMC layer thickness up to 120 lm, causing poor weldment strength. Recently, a solid-state joining technique, known as friction stir welding (FSW), has been attempted and proven advantageous to obtain similar Al and dissimilar Al-Mg joints with good strength.[6,7] The better weld quality during the FSW process can be attributed to moderately low and controllable heat input and intense plastic deformation with appreciably higher strain rate into the SZ, which in turn minimizes the probability of defects and IMC formation.[8–11] The Al/Mg alloy joints made with the FSW process can be employed in automotive and aerospace industries for manufacturing several structural parts for both civil and military applications, such as the gearbox assembly and the generator in defense helicopters and car bodies, primarily prone to exposure in corrosive atmospheres.[2] During the FSW of Al and Mg alloys, Dorbane et al.[12] have reported better joint strength, fewer defects, and astonishing surface quality. Czechowski[13] has found that the fatigue life of friction-stir-welded Al/ Mg alloy joints was comparatively higher than that of the metal inert gas welded joints. Firouzdor and Kou[14] analyzed the effects of process parameters on the Al/Mg alloy joint quality. They noticed higher weldment strength when Mg was kept at the advancing side (AS). In a similar attempt, Simoncini and Forcellese[15]
observed that the joint strength of Al/Mg alloys was chiefly dependent on the process parameters, while the weldment elongations had minor variations. Per their findings, the tool with a pin could be more advantageous than the pinless one in the context of better joint quality. The welding parameters can influence the microstructure profile, which in turn governs the weldment mechanical and corrosion properties.[16] Giraud et al.[17] have proposed that the welding parameters could influence the material mixing, weld
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