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

Omer Ekinci

doi:10.1515/mt-2024-0101

Artikel

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

Omer Ekinci
Dr. Omer Ekinci, born in 1988, achieved his BSc in the Department of Mechanical Engineering, Faculty of Engineering, Uludag University, Bursa, Turkey, in 2010. He obtained his MSc in Advanced Manufacturing Technology & Systems Management, School of Mechanical, Aerospace and Civil Engineering, University of Manchester, Manchester, UK in 2014. He achieved his PhD at the Department of Mechanical Engineering, Faculty of Engineering and Architecture Bingol University, Bingol, Turkey in 2021. He is currently working as an Assistant Professor at Sivas University of Science and Technology, Sivas, Turkey. His research areas include laser welding, solid-state welding processes, and materials science.

Veröffentlicht/Copyright: 28. Juni 2024

Veröffentlicht von

Veröffentlichen auch Sie bei De Gruyter Brill

Manuskript einreichen Informationen für Autor*innen

Aus der Zeitschrift Materials Testing Band 66 Heft 9

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.

Keywords: friction stir lap welding; AZ31B Mg alloy; AISI 304 stainless steel; welding speed; mechanical properties

Corresponding author: Omer Ekinci, Sivas Bilim ve Teknoloji Üniversitesi, Sivas, 58000, Türkiye, E-mail: omerekinci@sivas.edu.tr

About the author

Omer Ekinci

Dr. Omer Ekinci, born in 1988, achieved his BSc in the Department of Mechanical Engineering, Faculty of Engineering, Uludag University, Bursa, Turkey, in 2010. He obtained his MSc in Advanced Manufacturing Technology & Systems Management, School of Mechanical, Aerospace and Civil Engineering, University of Manchester, Manchester, UK in 2014. He achieved his PhD at the Department of Mechanical Engineering, Faculty of Engineering and Architecture Bingol University, Bingol, Turkey in 2021. He is currently working as an Assistant Professor at Sivas University of Science and Technology, Sivas, Turkey. His research areas include laser welding, solid-state welding processes, and materials science.

Research ethics: Not applicable.
Author contributions: The author has accepted responsibility for the entire content of this manuscript and approved its submission.
Competing interests: The author states no conflict of interest.
Research funding: None declared.
Data availability: Not applicable.

References

[1] S. M. Manladan, Y. Zhang, S. Ramesh, Y. Cai, S. Ao, and Z. Luo, “Resistance element welding of magnesium alloy and austenitic stainless steel in three-sheet configurations,” J. Mater. Process. Technol., vol. 274, p. 116292, 2019, https://doi.org/10.1016/j.jmatprotec.2019.116292.Suche in Google Scholar

[2] Y. Li, et al.., “Microstructure evolution and mechanical properties of linear friction welded S31042 heat-resistant steel,” J. Mater. Sci. Technol., vol. 34, no. 4, pp. 653–659, 2018, https://doi.org/10.1016/j.jmst.2017.11.031.Suche in Google Scholar

[3] W. Chen, et al.., “Improvement in tensile strength of Mg/Al alloy dissimilar friction stir welding joints by reducing intermetallic compounds,” J. Alloys Compd., vol. 861, 2021, Art. no. 157942, https://doi.org/10.1016/j.jallcom.2020.157942.Suche in Google Scholar

[4] T. Wang, S. Shukla, B. Gwalani, M. Komarasamy, L. Reza-Nieto, and R. S. Mishra, “Effect of reactive alloy elements on friction stir welded butt joints of metallurgically immiscible magnesium alloys and steel,” J. Manuf. Process., vol. 39, pp. 138–145, 2019, https://doi.org/10.1016/j.jmapro.2019.02.009.Suche in Google Scholar

[5] X. Fu, K. Chen, Z. Zhang, K. Kondoh, M. Wang, and X. Hua, “Interfacial microstructure and mechanical property in friction stir welded Mg/Al joints under low rotation speed,” Sci. Technol. Weld. Join., vol. 26, no. 6, pp. 470–477, 2021, https://doi.org/10.1080/13621718.2021.1935155.Suche in Google Scholar

[6] G. Song, T. Li, J. Yu, and L. Liu, “A review of bonding immiscible Mg/steel dissimilar metals,” Materials, vol. 11, no. 12, p. 2515, 2018, https://doi.org/10.3390/ma11122515.Suche in Google Scholar PubMed PubMed Central

[7] M. Santella, E. Brown, M. Pozuelo, T. Y. Pan, and J. M. Yang, “Details of Mg–Zn reactions in AZ31 to galvanised mild steel ultrasonic spot welds,” Sci. Technol. Weld. Join., vol. 17, no. 3, pp. 219–224, 2013, https://doi.org/10.1179/1362171811y.0000000098.Suche in Google Scholar

[8] L. M. Liu and X. Zhao, “Study on the weld joint of Mg alloy and steel by laser-GTA hybrid welding,” Mater. Charact., vol. 59, no. 9, pp. 1279–1284, 2008, https://doi.org/10.1016/j.matchar.2007.10.012.Suche in Google Scholar

[9] L. Liu, L. Xiao, D. L. Chen, J. C. Feng, S. Kim, and Y. Zhou, “Microstructure and fatigue properties of Mg-to-steel dissimilar resistance spot welds,” Mater. Des., vol. 45, pp. 336–342, 2013, https://doi.org/10.1016/j.matdes.2012.08.018.Suche in Google Scholar

[10] X. Fu, K. Chen, C. Liu, M. Wang, X. Hua, “Microstructure and mechanical properties of dissimilar friction stir lap welding between AZ31 Mg alloy and DC01 steel,” Mater. Charact., vol. 187, Art. no. 111870, 2022, https://doi.org/10.1016/j.matchar.2022.111870.Suche in Google Scholar

[11] S. Kumar and C. Wu, “Suppression of intermetallic reaction layer by ultrasonic assistance during friction stir welding of Al and Mg based alloys,” J. Alloys Compd., vol. 827, 2020, Art. no. 154343, https://doi.org/10.1016/j.jallcom.2020.154343.Suche in Google Scholar

[12] Z. Liang, et al.., “Effect of tool offset and tool rotational speed on enhancing mechanical property of Al/Mg dissimilar FSW joints,” Metall. Mater. Trans. A, vol. 44, pp. 3721–3731, 2013, https://doi.org/10.1007/s11661-013-1700-4.Suche in Google Scholar

[13] M. Maurya, A. Maurya, and S. Kumar, “Variants of friction stir based processes: review on process fundamentals, material attributes and mechanical properties,” Mater. Test., vol. 66, no. 2, pp. 271–287, 2024, https://doi.org/10.1515/mt-2023-0196.Suche in Google Scholar

[14] Y. Meng, et al.., “Friction stir butt welding of magnesium alloy to steel by truncated cone-shaped stirring pin with threads,” J. Mater. Process. Technol., vol. 291, 2021, Art. no. 117038, https://doi.org/10.1016/j.jmatprotec.2020.117038.Suche in Google Scholar

[15] H. Xie, X. Chen, Y. Lu, M. Zhang, and Q. Zhang, “Forming mechanism and mechanical properties of dissimilar friction stir lap welds of 304 austenitic stainless steel to a Ti6Al4V alloy,” Mater. Test., vol. 63, no. 10, pp. 889–894, 2021, https://doi.org/10.1515/mt-2021-0017.Suche in Google Scholar

[16] Y. Lu, et al.., “Influence of welding parameters on the interface temperature field of TC4 titanium alloys/304 stainless steel friction stir lap joints,” Mater. Test., vol. 65, no. 4, pp. 479–493, 2023, https://doi.org/10.1515/mt-2022-0290.Suche in Google Scholar

[17] Y. C. Chen and K. Nakata, “Effect of surface states of steel on microstructure and mechanical properties of lap joints of magnesium alloy and steel by friction stir welding,” Sci. Technol. Weld. Join., vol. 15, no. 4, pp. 293–298, 2013, https://doi.org/10.1179/136217109X12568132624325.Suche in Google Scholar

[18] H. Kasai, Y. Morisada, and H. Fujii, “Dissimilar FSW of immiscible materials: steel/magnesium,” Mater. Sci. Eng., vol. 624, pp. 250–255, 2015, https://doi.org/10.1016/j.msea.2014.11.060.Suche in Google Scholar

[19] F. Tolun, “Effect of tool rotational speed and position on mechanical and microstructural properties of friction stir welded dissimilar alloys AZ31B Mg and Al6061,” Mater. Test., vol. 64, no. 5, pp. 714–725, 2022, https://doi.org/10.1515/mt-2021-2080.Suche in Google Scholar

[20] L. Cederqvist and A. P. Reynolds, “Factors affected the properties of friction stir welded aluminum lap joints,” Weld. Res. Suppl., pp. 281–287, 2001.Suche in Google Scholar

[21] C. Y. Lee, W. B. Lee, J. W. Kim, D. H. Choi, Y. M. Yeon, and S. B. Jung, “Lap joint properties of FSWed dissimilar formed 5052 Al and 6061 Al alloys with different thickness,” J. Mater. Sci., vol. 43, pp. 3296–3304, 2008, https://doi.org/10.1007/s10853-008-2525-1.Suche in Google Scholar

[22] M. Dehghani, A. Amadeh, and S. A. Mousavi, “Investigations on the effects of friction stir welding parameters on intermetallic and defect formation in joining aluminum alloy to mild steel,” Mater. Des., vol. 49, pp. 433–441, 2013, https://doi.org/10.1016/j.matdes.2013.01.013.Suche in Google Scholar

[23] T. Wang, X. Gong, S. Ji, G. Xue, and Z. Lv, “Friction stir lap welding thin aluminum alloy sheets,” High Temp. Mater. Process., vol. 39, no. 1, pp. 663–670, 2020, https://doi.org/10.1515/htmp-2020-0024.Suche in Google Scholar

[24] O. Ekinci, “Effect of tool rotational speed on friction stir spot welds of AZ31B Mg alloy to AISI 304 stainless steel,” Mater. Test., vol. 66, no. 4, 2024. https://doi.org/10.1515/mt-2023-0372.Suche in Google Scholar

[25] H. I. Khalaf, R. Al-Sabur, and H. A. Derazkola, “Effect of number of tool shoulders on the quality of steel to magnesium alloy dissimilar friction stir welds,” Arch. Civ. Mech. Eng., vol. 23, 2023, Art. no. 125, https://doi.org/10.1007/s43452-023-00673-z.Suche in Google Scholar

[26] Q. Zhong, D. Pan, S. Zuo, X. Li, H. Luo, and Y. Lin, “Fabrication of Mg–Zn intermetallic layer with high hardness and corrosion resistance on AZ31 alloy,” Mater. Charact., vol. 179, 2021, Art. no. 111365, https://doi.org/10.1016/j.matchar.2021.111365.Suche in Google Scholar

[27] M. Vogel, O. Kraft, G. Dehm, and E. Arzt, “Quasi-crystalline grain-boundary phase in the magnesium die-cast alloy ZA85,” Scr. Mater., vol. 45, no. 5, pp. 517–524, 2001, https://doi.org/10.1016/S1359-6462(01)01052-1.Suche in Google Scholar

[28] Z. Bojar and W. Przetakiewicz, Materiały metalowe z udziałem faz międzymetalicznych. [In Polish: Metallic materials with intermetallic phases], Warsaw, BEL Studio, 2006.Suche in Google Scholar

[29] T. Takasugi, O. Ozumi, and N. Masahashi, “Electronic and structural studies of grain boundary strength and fracture in Ll2 ordered alloys–II. On the effect of third elements in Ni3Al alloy,” Acta Metall., vol. 33, no. 7, pp. 1259–1269, 1985, https://doi.org/10.1016/0001-6160(85)90237-8.Suche in Google Scholar

[30] A. Inoue, T. Masumoto, and H. Tomioka, “Microstructure and mechanical properties of rapidly quenched L20 and L20+L12 alloys in Ni-Al-Fe and Ni-Al-Co systems,” J. Mater. Sci., vol. 19, pp. 3097–3106, 1984, https://doi.org/10.1007/BF01026989.Suche in Google Scholar

[31] C. H. Tsau, J. S. C. Jang, and J. W. Yeh, “Microstructures and mechanical behaviors of Ni Al Fe intermetallic compounds,” Mater. Sci. Eng., A, vol. 152, nos. 1–2, pp. 264–268, 1992, https://doi.org/10.1016/0921-5093(92)90077-E.Suche in Google Scholar

[32] C. T. Liu, “Ductility and fracture behavior of polycrystalline Ni3Al alloys,” MRS Online Proc. Libr., vol. 81, pp. 355–367, 1986, https://doi.org/10.1557/PROC-81-355.Suche in Google Scholar

[33] S. J. Huang, S. D. Midyeen, M. Subramani, and C. C. Chiang, “Microstructure evaluation, quantitative phase analysis, strengthening mechanism and influence of hybrid reinforcements (β-SiCp, Bi and Sb) on the collective mechanical properties of the AZ91 magnesium matrix,” Metals, vol. 11, no. 6, 2021, Art. no. 898, https://doi.org/10.3390/met11060898.Suche in Google Scholar

[34] L. Dubourg, A. Merati, and M. Jahazi, “Process optimisation and mechanical properties of friction stir lap welds of 7075-T6 stringers on 2024-T3 skin,” Mater. Des., vol. 31, no. 7, pp. 3324–3330, 2010, https://doi.org/10.1016/j.matdes.2010.02.002.Suche in Google Scholar

[35] Y. Song, X. Yang, L. Cui, X. Hou, Z. Shen, and Y. Xu, “Defect features and mechanical properties of friction stir lap welded dissimilar AA2024-AA7075 aluminum alloy sheets,” Mater. Des., vol. 55, pp. 9–18, 2014, https://doi.org/10.1016/j.matdes.2013.09.062.Suche in Google Scholar

Published Online: 2024-06-28

Published in Print: 2024-09-25

Sie haben derzeit keinen Zugang zu diesem Inhalt.

Artikel in diesem Heft

https://doi.org/10.1515/mt-2024-0101

Schlagwörter für diesen Artikel

friction stir lap welding; AZ31B Mg alloy; AISI 304 stainless steel; welding speed; mechanical properties