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Fatigue life of friction stir spot welds between Z91 magnesium alloy and ENAW7075-T651 aluminum alloy

  • 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 and 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.

     EMAIL logo     and Zulkuf Balalan

    Dr. Zulkuf Balalan, born in 1970, achieved his BSc in the Machine Department, Faculty of Technical Education, University of Firat, Elazig, Turkey, in 1996 and his MSc in the same department in 2004. In 2013, he achieved his PhD at the same university. Since 2014, he has been Assistant Professor at Bingol University in Turkey. His research areas include solid-state welding processes, materials science, composite materials, powder metallurgy, and manufacturing techniques.
Published/Copyright: November 27, 2024
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Materials Testing
From the journal Materials Testing Volume 67 Issue 1

Abstract

Magnesium (Mg) and aluminum (Al) alloys are considered to be among the lightest structural metals. Using these materials in a design can considerably decrease weight, which brings many benefits like reducing fuel consumption and increasing the performance of an aircraft or a ground vehicle. However, these alloys are too difficult to be joined via fusion welding techniques. In this context, welding AZ91 Mg alloy to ENAW7075-T651 Al alloy by the solid-state welding method of friction stir spot welding was investigated comprehensively. These alloys were welded by utilizing a tool with a triangle pin and various tool rotational speeds (1,000, 1,400, and 1,800 rpm) and welding times (3 and 6 s). Macro and microstructure of the welds and their hardness, tensile strength, and tension-compression fatigue life were determined. Generally, an improvement in the mechanical properties of the weld was observed by increasing the welding time due to the expansion of the joining area. The welding with the best mechanical properties was obtained at 1,400 rpm, and the worst at 1,800 rpm. All the welds failed from the weld area during the tensile and fatigue tests and exhibited a brittle fracture mode due to the formation of intermetallic compounds in the welds.

Keywords: friction stir spot welding; AZ91 Mg alloy; 7075-T651 Al alloy; macro and microstructure; tensile shear strength; fatigue life
Corresponding author: Omer Ekinci, Department of Astronautical Engineering, Faculty of Aviation and Space Sciences, Sivas University of Science and Technology, Sivas, Türkiye, E-mail:

Funding source: Bingol University Scientific Research Projects Unit (BUBAP) under the project of BAP-MMF.2019.00.001.

About the authors

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 and 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.

Zulkuf Balalan

Dr. Zulkuf Balalan, born in 1970, achieved his BSc in the Machine Department, Faculty of Technical Education, University of Firat, Elazig, Turkey, in 1996 and his MSc in the same department in 2004. In 2013, he achieved his PhD at the same university. Since 2014, he has been Assistant Professor at Bingol University in Turkey. His research areas include solid-state welding processes, materials science, composite materials, powder metallurgy, and manufacturing techniques.

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interests: The authors state no conflict of interest.

  6. Research funding: The authors would like to thank Bingol University for financial support of Bingol University Scientific Research Projects Unit (BUBAP) under the project of BAP-MMF.2019.00.001.

  7. Data availability: Not applicable.

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Published Online: 2024-11-27
Published in Print: 2025-01-29

© 2024 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. The effect of MWCNT concentration on the electrical resistance change characteristic of glass/fiber epoxy composites under low cycle fatigue loading
  3. Effect of TMAB and ZrC concentration on mechanical and morphological properties of Ni–B/ZrC composite electrodeposition
  4. Influence of pulse duration and frequency of laser surface texturing on the surface roughness and microstructure of CoCr28Mo alloy for biomedical applications
  5. Comparison of Ni-based SiC and B4C reinforcements on a TIG-coated AISI 1040 steel
  6. Fatigue life of friction stir spot welds between Z91 magnesium alloy and ENAW7075-T651 aluminum alloy
  7. Effect of wire feed speed and arc length on weld bead geometry in synergistic controlled pulsed MIG/MAG welding
  8. Structural and morphological behavior of Al-based hybrid composites reinforced by SiC and WS2 inorganic material
  9. Impact behavior of natural material-based sandwich composites
  10. Effects of different production methods and hybridization on mechanical characteristics of basalt, flax, and jute fiber-reinforced composites
  11. Effect of heat treatment on interface characteristics and mechanical properties of explosive welded Cu/Ti composites
  12. Enhanced mechanical properties of Sr-modified Al–Mg–Si alloy by thermo-mechanical treatment
  13. Mechanical properties of laser welded similar and dissimilar steel joints of TBF1050 and DP1000 steel sheets
  14. Mechanical behavior of composite pipe structures under compressive force and its prediction using different machine learning algorithms
  15. Advanced structural design of engineering components utilizing an artificial neural network and GNDO algorithm
  16. Energy efficiency in materials testing by reactive power – part 1: power recirculating method in wear testing
https://doi.org/10.1515/mt-2024-0175
Keywords for this article
friction stir spot welding; AZ91 Mg alloy; 7075-T651 Al alloy; macro and microstructure; tensile shear strength; fatigue life

Articles in the same Issue

  1. Frontmatter
  2. The effect of MWCNT concentration on the electrical resistance change characteristic of glass/fiber epoxy composites under low cycle fatigue loading
  3. Effect of TMAB and ZrC concentration on mechanical and morphological properties of Ni–B/ZrC composite electrodeposition
  4. Influence of pulse duration and frequency of laser surface texturing on the surface roughness and microstructure of CoCr28Mo alloy for biomedical applications
  5. Comparison of Ni-based SiC and B4C reinforcements on a TIG-coated AISI 1040 steel
  6. Fatigue life of friction stir spot welds between Z91 magnesium alloy and ENAW7075-T651 aluminum alloy
  7. Effect of wire feed speed and arc length on weld bead geometry in synergistic controlled pulsed MIG/MAG welding
  8. Structural and morphological behavior of Al-based hybrid composites reinforced by SiC and WS2 inorganic material
  9. Impact behavior of natural material-based sandwich composites
  10. Effects of different production methods and hybridization on mechanical characteristics of basalt, flax, and jute fiber-reinforced composites
  11. Effect of heat treatment on interface characteristics and mechanical properties of explosive welded Cu/Ti composites
  12. Enhanced mechanical properties of Sr-modified Al–Mg–Si alloy by thermo-mechanical treatment
  13. Mechanical properties of laser welded similar and dissimilar steel joints of TBF1050 and DP1000 steel sheets
  14. Mechanical behavior of composite pipe structures under compressive force and its prediction using different machine learning algorithms
  15. Advanced structural design of engineering components utilizing an artificial neural network and GNDO algorithm
  16. Energy efficiency in materials testing by reactive power – part 1: power recirculating method in wear testing
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