Enhancing the tensile performance of Al/Mg alloy dissimilar friction stir welded joints by reducing brittle intermetallic compounds

Mukesh Kumar; Ashish Das; Raj Ballav; Niraj Kumar; Keshav K. Sharma

doi:10.1515/ijmr-2021-8690

Article

Enhancing the tensile performance of Al/Mg alloy dissimilar friction stir welded joints by reducing brittle intermetallic compounds

Mukesh Kumar , Ashish Das , Raj Ballav , Niraj Kumar and Keshav K. Sharma

Published/Copyright: November 28, 2023

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From the journal International Journal of Materials Research Volume 115 Issue 1

Abstract

In this current research work, magnesium AZ61 (Advancing Side) and aluminum 6061-T6 (Retreating Side) alloys were joined using the zinc interlayer friction stir welding technique at the optimum process parameters. The aim of this work is to propose an effective alternative to overcome issues related to aluminum/magnesium joints. This article investigates the effects of zinc foil (0.2 mm) on the weld surface (3 mm aluminum/magnesium plates), intermetallic compound characteristics, microstructure, fracture surface and strength of joint. The emergence and nature of intermetallic compounds during aluminum/magnesium and aluminum/zinc/magnesium friction stir welded joints were studied in detail. As can be seen from the findings, using zinc in aluminum/magnesium friction stir welded joints inhibits the emergence of brittle aluminum–magnesium intermetallic compounds and promotes the formation of magnesium–zinc intermetallic compounds in the stir zone by introducing the zinc interlayer, confirmed through X-ray diffraction analysis. Furthermore, the average tensile performance (181.33 MPa) of friction stir welded aluminum/zinc/magnesium joints was enhanced up to 18.26 % compared to aluminum/magnesium friction stir welded joints (153.33 MPa). The promising results of this research establish an alternative route with a cost-effective technique to enhance the aluminum/magnesium dissimilar joint strength.

Keywords: Friction stir welding; Intermetallic compounds; Zinc interlayer; Mechanical properties; Dissimilar aluminum/magnesium joints

Corresponding author: Ashish Das, Department of Production and Industrial Engineering, National Institute of Technology, Jamshedpur, 831014 Jharkhand, India, E-mail: ashishdas.prod@nitjsr.ac.in, https://nitjsr.irins.org/profile/100484

Acknowledgements

The testing and characterization facilities of IIT Kanpur (ACMS Lab), NIT Rourkela, Central workshop NIT Jamshedpur are gratefully acknowledged. The authors want to express their sincere gratitude to Mr. Iqbal Ansari and Mr. Yogendra Pratap Singh for their invaluable support in the efficacious conduction of experimental and characterization work.

Research ethics: Not applicable.
Author contributions: Mukesh Kumar: investigation, formal analysis, writing – original draft; Ashish Das: conceptualization. supervision, methodology, writing – review & editing; Raj Ballav: supervision, writing – review & editing; Niraj Kumar: experimentation; Keshav K. Sharma: testing.
Competing interests: The authors declare no conflicts of interest regarding this article.
Research funding: The authors would wish to thank the Ministry of Education and Government of India (PhD Scholarship Grant No:O.O.NO.NITJSR/ACAD/2018/443), for providing essential financial assistance.
Data availability: Not applicable.

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Received: 2021-12-08

Accepted: 2023-03-23

Published Online: 2023-11-28

Published in Print: 2024-01-29

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Articles in the same Issue

https://doi.org/10.1515/ijmr-2021-8690

Keywords for this article

Friction stir welding; Intermetallic compounds; Zinc interlayer; Mechanical properties; Dissimilar aluminum/magnesium joints