Welded Magnesium Alloy Research Articles

Effects of water cooling of friction stir welding of magnesium alloy stiffness joint

This study presents a comparative analysis of friction stir welding (FSW) and underwater friction stir welding (UFSW) of AZ31 magnesium alloy in T-configuration, emphasizing the effects on heat distribution, material properties, and mechanical performance. Simulation results revealed a more uniform heat distribution in both welding techniques, with the hottest area on the advancing side. The maximum temperatures recorded at the shoulder-workpiece contact were 404 °C for FSW and 349 °C for UFSW, a 13.6 % reduction in UFSW. Material velocity at the trailing edge was 63 mm/s for FSW and 42 mm/s for UFSW, showing a 34 % decrease due to lower heat generation in UFSW. Strain rates were 450 s⁻¹ for FSW and 420 s⁻¹ for UFSW. Grain size in the stir zone was 26 micrometers for FSW and 21 micrometers for UFSW, a 19 % reduction. Ultimate tensile strength (UTS) increased by 6 % in the skin direction and 12.8 % in the flange direction for UFSW compared to FSW. SEM analysis indicated enhanced ductility in UFSW fractures. These results demonstrate UFSW's superiority in improving thermal management, microstructural properties, and mechanical performance of welded joints.

Monitoring of the Weld Pool, Keyhole Morphology and Material Penetration State in Near-Infrared and Blue Composite Laser Welding of Magnesium Alloy

The laser welding of magnesium alloys presents challenges attributed to their low laser-absorbing efficiency, resulting in instabilities during the welding process and substandard welding quality. Furthermore, the complexity of signals during laser welding processes makes it difficult to accurately monitor the molten state of magnesium alloys. In this study, magnesium alloys were welded using near-infrared and blue lasers. By varying the power of the near-infrared laser, the energy absorption pattern of magnesium alloys toward the composite laser was investigated. The U-Net model was employed for the segmentation of welding images to accurately extract the features of the melt pool and keyhole. Subsequently, the penetrating states were predicted using the convolutional neural network (CNN), and the novel approach employing Local Binary Pattern (LBP) features + a backpropagation (BP) neural network was applied for comparison. The extracted images achieved MPA and MIoU values of 89.54% and 81.81%, and the prediction accuracy of the model can reach up to 100%. The applicability of the two monitoring approaches in different scenarios was discussed, providing guidance for the quality of magnesium welding.

Formation and mechanical properties of AZ31B magnesium alloy welds by power-modulated oscillating laser

an energy-space modulated laser was proposed in welding workpieces with AZ31B magnesium alloy to enhance the efficiency of heat transfer and reduce defects of welds, and the proposed laser was power-modulated oscillating laser (PMOL). To validate the performance of the proposed technique, non-penetration welding and butt welding were conducted on the workpieces with a thickness of 5 mm. The impact of power-modulation parameters was investigated at the aspects of micro-structures, appearance, and mechanical properties of welds. The results showed that in comparison with a conventional laser (CL) or circular oscillation laser (COL), an energy-space modulated laser led to (1) an increased depth of weld penetration and (2) an enhanced coupling efficiency of laser energy. The parameters of power modulation could be optimized to reduce the defects of welds such as spatter, underfill, and thick fish scales significantly reduced; it refined the equiaxed grains in the center area of weld. When the frequency and amplitude of power-modulation were set as 50 Hz and 500 W, respectively, the mechanical properties of the weld were improved with the ultimate tensile strength of 238 MPa and an elongation ratio of 13.9 % which were 96.1 % and 58.7 % of those of the base material (BM), respectively. In comparison with the results welded by CL and COL, the ultimate tensile strength by PMOL was increased by 13.9 % and 4.4 %, and the elongation was increased by 54.4 % and 8.6 %, respectively.

Numerical simulation and experimental investigation on friction stir welding of AZ31 magnesium alloy

Integrated numerical simulations and experimental investigations were employed to scrutinize the thermal, mechanical, and microstructural transformations of the AZ31 magnesium alloy during the friction stir welding (FSW) process. Especially, the primary focus was on the influence of process parameters such as rotational speed and welding speed on the temperature distribution, grain refinement, and mechanical properties of welded joints in alloys. By employing Deform-3D coupled with the integration of constitutive equations and dynamic recrystallization (DRX) models, the FSW process was investigated. The investigation revealed a significant increase in temperature when the tool’s shoulder made contact with the weld, resulting in the substantial accumulation of heat during FSW. Distinctions became apparent between the advancing side (AS) and the receding side (RS), with the AS exhibiting slightly elevated levels of temperature, equivalent stress, strain, and grain size. Specifically, adjustments in the rotational speed of the stirring tool and a reduction in welding speed resulted in larger grain sizes within the alloy. For example, when the rotational speed was set at 1200 rpm and the travel rate was 200 mm min−1, the initial grain size of the weld experienced a substantial decrease from 57.8 μm to 8.2 μm. Subsequent experimental verification, considering grain size and microhardness, was carried out to optimize FSW parameters for achieving the desired material properties. The accuracy of simulation results was validated through a meticulous comparison with experimental findings, underscoring the potential of numerical simulation in comprehending and predicting FSW processes.

Friction stir lap welding of AZ31B magnesium alloy to AISI 304 stainless steel

Abstract AZ31B magnesium alloy plates were lap-joined to AISI 304 stainless steel plates through the friction stir welding (FSW) method and utilizing various tool welding speeds. It has been found that the most important factor governing the weld strength is the hook formed on the advancing side of the welds. The weld tensile shear strength improved with an increase in the tool feed rate. Because, in general, height, length, and width of the hook taking place on the advancing side shrunk. Furthermore, the angle between the hook and interface of the plates increased, leading to reduced sharp corner formation. Apart from these, imperfections such as cavities, voids, and uncombined regions at the weld interface reduced and disappeared when increasing the welding speed. During the tensile shear test, all the welds fractured tensile mode and brittle type from the top AZ31B plate next to the hook on the advancing side. There was no breakage occurred in the weld interface, which is an indication of the strong joints. No intermetallic compounds between iron and magnesium were determined at the fracture region. At lower welding speeds, a higher amount of AISI 304 particles occurred at the weld stir zone resulting in a higher hardness.

Microstructure and strengthening mechanism of TIG welded joint of AZ31 alloy based on FSP technique

Magnesium alloys, renowned for their outstanding properties, present promising applications within the realm of advanced manufacturing. Addressing the challenges of coarse grains and inferior properties in the fusion welding of magnesium alloys, a novel strengthening approach for fusion-welded joints is proposed in this study. This method employs fine, uniform, and dense grains as the matrix, with particle-reinforced structures serving as the strengthening backbone. By utilizing powder feeding in conjunction with fusion welding and friction stir processing, ideal microstructures were successfully fabricated, and the mechanisms influencing grain morphology and joint properties were explored. Following the strengthening treatment, the grain size of the magnesium alloy molten weld was reduced from 193.5 μm to 15.9 μm, resulting in a grain refinement efficacy of 91.8 %. Concurrently, the tensile strength was augmented by 70.2 MPa, and the elongation experienced a 136 % enhancement. The grain morphology, eutectic phase structure, texture strength, precipitated phase type and dislocation distribution at each processing stage of the welded joint were observed. Research shows that nano-enhanced particles adhere to the eutectic structure of grain boundaries, effectively inhibiting the diffusion of solute elements and significantly reducing the dendrite growth rate. It is the main mechanism by which reinforced particles lead to grain refinement. Discontinuous recrystallization during FSP treatment leads to grain refinement, work hardening and enhanced pinning of particles at grain boundaries, which are the main reasons for the strength improvement.

Use of threaded cylindrical pin tools to reduce macroscopic defects in dissimilar welded joints of AA7075-T6 and AZ31B alloys by the FSW process

The continued increase in greenhouse gas emissions has had dire consequences for the global climate. In order to reduce such emissions, several efforts have been made by researchers in the transport sector, such as the development of electric motorization, the development of hybrid engines, the use of biofuels and the use of light alloys. The use of light alloys such as aluminum and magnesium in vehicles can reduce the emission per kilogram of vehicles drastically, however, it is still necessary to develop effective and more agile methods of the dissimilar joints of these materials. Some authors have studied the friction stir welding of AZ31B magnesium alloys and AA7075-T6 aluminum alloys in order to determine better process parameters to enable this bond, however, few articles have been published in order to evaluate the influence of tool geometry on such properties. In this sense, this article aims to evaluate the influence of friction welding tool pin geometry as smooth cylindrical pin, threaded cylindrical pin, conical and hexagonal pin configurations in the formation of the mixed zone of welds manufactured by the FSW process. For this purpose, AZ31B and AA7075-T6 alloys were welded by FSW with welding speed of 75 mm/min, tool rotation speed of 565 rpm, offset of 0.5mm and inclination of the tool geometry in relation to the plates to be welded of 3º, the joints were evaluated for their macro and microstructures and Vickers hardness with a load of 100 gf. It was possible to observe that the joints welded with the threaded cylindrical pin tool presented stir zones free of macroscopic defects, similar hardness values for the four tools studied and the presence of a thin layer of intermetallics between TMAZ and SZ on the AZ31B side.

Investigation on submerged friction stir welding of AZ31B magnesium alloy under the influence of rotation speed

In this study, submerged friction stir welding (SFSW) was performed to weld 6 mm thick AZ31B Mg alloy plates, aiming to explore the impact of rotation speed on microstructure and tensile behavior. The water medium was used to submerge the samples. The SFSW was conducted at three different speeds (815, 960, and 1200 rpm), to assess the impact of rotation speed on SFSWed joint performance. As the rotation speed increased from 815 to 960 rpm, tensile strength increased plateauing over a range of the rotation speed. However, a significant drop in tensile strength occurred at 1200 rpm due to the formation of void defects. The SZ exhibits a size and width increment in the lower part with increasing rotation speed. The hardness of the stir zone (SZ) gradually rose with increasing rotation speed from 815 to 960 rpm. Fracture locations were observed in the thermal-mechanically affected zone (TMAZ) adjacent to the SZ at a rotation speed of 815 rpm, and in the heat-affected zone (HAZ) adjacent to the TMAZ at a rotation speed of 960 rpm. The joint welded at 1200 rpm fractured within the SZ. This study offers valuable insights into the welding and joining field, particularly regarding their mechanical characteristics.

Modeling and Simulation of Friction Stir Welding of Aluminum and Magnesium Alloys Using Finite Element Analysis

Modeling and Simulation of Friction Stir Welding of Aluminum and Magnesium Alloys Using Finite Element Analysis

Interrupted tensile tests to reveal the non-uniform tensile deformation of AZ31 magnesium alloy welding joint processed by friction stir welding

Interrupted tensile tests to reveal the non-uniform tensile deformation of AZ31 magnesium alloy welding joint processed by friction stir welding

Corrosion and protection of friction stir welding of magnesium alloy

Purpose The high specific strength makes magnesium alloys have a wide range of applications in aerospace, military, automotive, marine and construction industries. However, its poor corrosion resistance and weldability have limited its development and application. Friction stir welding (FSW) can effectively avoid the defects of fusion welding. However, the microstructure, mechanical properties and corrosion behavior of FSW joints in magnesium alloys vary among different regions. The purpose of this paper is to review the corrosion of magnesium alloy FSW joints, and to summarize the protection technology of welded joints. Design/methodology/approach The corrosion of magnesium alloy FSW joints includes electrochemical corrosion and stress corrosion. This paper summarizes corrosion protection techniques for magnesium alloys FSW joints, focusing on composition, microstructure changes and surface treatment methods. Findings Currently, this research is mainly focused on enhancing the corrosion resistance of magnesium alloy FSW joints by changing compositions, structural modifications and surface coating technologies. Refinement of the grains can be achieved by adjusting welding process parameters, which in turn minimizes the effects of the second phase on the alloy’s corrosion resistance. Originality/value This paper presents a comprehensive review on the corrosion and protection of magnesium alloys FSW joints, covering the latest research advancements and practical applications. It aims to equip researchers with a better insight into the field and inspire new studies on this topic.

Advances in ultrasonic welding of lightweight alloys: A review

Abstract The lightweight alloy sheet materials have been widely used in industries such as automobiles, aviation, and aerospace. However, there are huge challenges in the structural joining process. Likewise, industries are probing new technologies and are rapidly adapting to more complex light alloy materials. The ultrasonic metal welding is a reliable solid-phase joining technology, which has incomparable development prospects in the high-strength joining of lightweight alloy sheet materials. This article summarizes the research progress of ultrasonic welding of aluminum alloy, magnesium alloy, and titanium alloy thin plates in recent years. The key features of this review article are the ultrasonic welding process, advantages, applications, and limitations. It introduces the welding process parameters to explore the breakthroughs for straightforward direction. Furthermore, to strengthen the phenomena, the current state of the ultrasonic welding of lightweight alloys and their future perspectives are also reflected.

Effect of preheating temperature on the defects in pulsed laser welding of sheet AZ31 magnesium alloy

To suppress the welding defects of thin sheet magnesium alloy by pulsed laser welding, AC-300 W pulsed laser welder is used to weld 1 mm magnesium alloy at different preheating temperatures, and the effect of preheating temperature on solidification cracks, pore and undercut are studied. Preheating temperature is set at 25 ℃, 100 ℃, 150 ℃, 200 ℃, 250 ℃, 300 ℃ and 350 ℃. Results show that preheating increases the peak temperature (1494.14 ℃ to 1785.86 ℃) and reduces the cooling rate (14489.33 ℃/s to 14282.11 ℃/s) of the molten pool, thereby reducing welding defect sensitivity. When preheated at 200 ℃, the solidification cracks and pores disappear, and the undercut depth reaches the minimum value of 0.04 mm.

Vacuum laser beam welding of AZ31 magnesium alloy: Weld formability, microstructure and mechanical properties

Laser welding of magnesium alloy is still challenging because of the frequently occurred defects. In this work, a promising vacuum laser welding technique was used to join AZ31 magnesium alloy. The effect of ambient pressure on weld surface appearances and weld fusion cross sections was symmetrically investigated. It was found that the penetration depth increased and the weld width became narrower with the descending of ambient pressure from 101 kPa to 10 kPa. However, the penetration depth did not increase and even decreased when the ambient pressure further decreased to 1 kPa and 0.1 kPa. In addition, hump defects occurred at lower ambient pressure of 1 kPa and 0.1 kPa. The weld pool and keyhole behaviors were in-site observed using a high-speed camera at various ambient pressures. The results showed that unstable keyhole and turbulent flow were found in the molten pool at 101 kPa. The keyhole became more stable as the ambient pressure decreased from 101 kPa to 10 kPa. When the ambient pressure further decreased to 1 kPa and 0.1 kPa, the liquid metal thickness between keyhole wall and weld pool periphery became very narrow, which sometimes resulted in unstable absorption of the laser energy. Finally, a 10 mm-thick bottom-locking weld was made under vacuum. The average grain diameter of the weld in vacuum is 28.4 μm, which is much lower than 46 μm in atmosphere. The tensile results showed that the average ultimate tensile strength and the elongation of the joints welded in vacuum at 10 kPa was 8.8 % and 44.0 % higher than that of the joints welded in atmosphere respectively. The enhanced mechanical properties were attributed to the reduced porosity and refined microstrustures of the weld joint made under vacuum.

Effect of notch location on fatigue crack growth behavior for inhomogeneous material domains in friction stir welded magnesium alloy

The fatigue crack growth behavior of friction stir welded joints of AZ31 Mg alloy is investigated for three different notch locations. The extended finite element method based simulation is developed to capture the effect of stir zone on fatigue crack growth behavior. The notch locations with asymmetric material domain experience an asymmetric stress field, which leads to crack path deviation from the orthogonal direction to the applied force. This leads to a longer crack path. The near-tip stress field from the simulation enhances the understanding of unusual crack path. The experimental results including crack path trajectories from experiments compare well against the numerical predictions.

The influence of welding speed on nanosecond laser welding of AZ31B magnesium alloy and 304 stainless steel

Nanosecond pulse laser welding was performed on AZ31B magnesium alloy and 304 stainless steel to investigate the impact of welding speed on the joining process. The temperature field of the magnesium/steel laser welding process was simulated using COMSOL software. The findings revealed that a welding speed of 10 mm/s resulted in significant spattering and larger porosity defects in the joint due to excessive heat input. However, when the welding speed was increased to 30 mm/s, these defects disappeared, and the porosity decreased to a minimum, leading to an increased bonding area at the interface. As the speed increased, the heat input decreased, making it more challenging for the porosity to escape from the molten pool and resulting in the formation of larger pores. The shear force test results indicated that the highest shear force was 298.7 N at a welding speed of 30 mm/s. The reduction in porosity and greater penetration depth of the magnesium alloy contributed to the desired mechanical performance. Additionally, the fracture modes were classified as button pullout failure (BPF), base material tearing failure (BTF), and interface failure (IF). The outermost weld seam served as the initial fracture path for both BPF and BTF modes, with BTF ultimately fracturing in the steel base material during tearing. Oxide inclusions, porosity, and the angle of distortion contributed to the fracture path of IF.

Tensile Test on Friction Stir Welded AZ31B and AZ91B Magnesium Alloys

Rare earth materials containing magnesium alloy AZ91B and AZ31B is finding widespread use in the automotive, aerospace and military industries due to its greater strength-to-weight ratio and formability. Magnesium is typically regarded as difficult to fuse together through material fusion procedures due to flaws found in welding inclusions, porosity and welded junction distortions. Friction stir welding solid state joining procedure is used for Mg joining alloys successfully. The process variables influencing the combined characteristics of weldments include tool pin geometry, downward axial force, tool welding speed (rpm). In the current research, five distinct tool types were used to create friction stir weldment geometries. There were 18 trials overall with 3 components and 8 stages run in accordance with the primary composite design matrix. The information produced by a mathematical model through response surface approach was sufficient for the developed ANOVA was used to verify the model. Large interaction between welding parameters and tensile strength graphs are utilised to depict its behaviour. It was discovered that the cylindrical straight pin has the greatest tensile qualities. The mathematical model is beneficial for adjusting the tensile strength forecast to enhance the weld quality by choosing suitable process parameters for AZ31B and AZ91B welded magnesium alloys.

Effect of Traverse Speed Variation on Microstructural Properties and Corrosion Behavior of Friction Stir Welded WE43 Mg Alloy Joints.

The growing demand for Magnesium in the automotive and aviation industries has enticed the need to improve its corrosive properties. In this study, the WE43 magnesium alloys were friction stir welded (FSW) by varying the traverse speed. FSW eliminates defects such as liquefication cracking, expulsion, and voids in joints encountered frequently in fusion welding of magnesium alloys. The microstructural properties were scrutinized using light microscopy (LM) and scanning electron microscopy (SEM). Additionally, the elemental makeup of precipitates was studied using electron dispersive X-ray spectroscopy (EDS). The electrochemical behavior of specimens was evaluated by employing potentiodynamic polarization tests and was correlated with the microstructural properties. A defect-free weldment was obtained at a traverse and rotational speed of 100 mm/min and 710 rpm, respectively. All weldments significantly improved corrosion resistance compared to the base alloy. Moreover, a highly refined microstructure with redistribution/dissolution of precipitates was obtained. The grain size was reduced from 256 µm to around 13 µm. The corrosion resistance of the welded sample was enhanced by 22 times as compared to the base alloy. Hence, the reduction in grain size and the dissolution/distribution of secondary-phase particles within the Mg matrix are the primary factors for the enhancement of anti-corrosion properties.

Consumable-free dissimilar joining of Mg to steel using a laser-arc hybrid heat source

Laser-arc hybrid direct lap welding offers an effective method for achieving high-performance welding of magnesium (Mg) alloys to steel. In this study, we optimized the mechanical properties of dissimilarly joined Mg and steel by controlling the offset of the laser heat source which directly affected the power delivered to the workpiece. We analyzed the variation of wetting angle and the mechanism of strengthening and tensile failure of the joints, with the results showing that under ideal processing conditions, the tensile strength of the direct lap welded joint without filler wire or any interlayers reached 295.7 N/mm, which is approximately 80% of the Mg alloy's nominal strength – an improvement that has not been previously reported in the literature. The laser improved the wettability of the joint and the laser keyhole played a critical role in pinning the weld seam, increasing the area of the interfacial reaction layer, and transferring the location of the crack source to strengthen the joint performance.

Challenges on friction stir welding of magnesium alloys in automotives

The most important advancement in metal joining during the last few decades is the Friction Stir Welding (FSW) process. When welding magnesium or light weight alloys, FSW offers several benefits. Due to its advantages in lightweight construction, friction stir welding of magnesium alloys are widely used in the aerospace, marine, transport sector, particularly in automobiles and trucks, where they may significantly increase fuel economy and reduce emissions. Research and development in the area of FSW and related technologies have recently been advancing quickly on a global scale. The fundamentals of friction stir welding and a number of characteristics of friction stir welded magnesium alloys have been discussed in this article. Furthermore, this review reports the summary of the present status of friction stir welding of magnesium alloys with automotive applications. In addition to that, the properties, structure, flammability and wear behavior of magnesium alloys have been described.