Abstract
Mg-Al joining is problematic due to dissimilar high-temperature flow characteristics that often result in defects and brittle intermetallic compounds (IMC) at the interface. Process development on lap joining of 1.27 mm 6022 (top sheet) and 1.5 mm ZEK100 (bottom sheet) intended for an automotive door application is presented. Process development was conducted in linear welding using power control (modulating torque and spindle speed) with multiple tool designs and welding parameters. Process variables were correlated to micro- and macro-structure and mechanical properties. A 2D computational model was created to understand the failure mechanism and contribution of mechanical interlocking towards joint strength. Joint efficiency of 48% (compared to base 6022 Al) at a welding speed of 0.625 m/min has been demonstrated thus far. For a thin (<2 mm) automotive sheet with a softer material as a bottom sheet, adequate control of process variables is critical to maintain weld stability and avoid excessive IMC layer at the interface. A combination of mechanical anchoring and metallurgical reaction is likely responsible for bonding.
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Acknowledgements
PNNL is operated by Battelle Memorial Institute for the U.S. Department of Energy under contract DE-AC05-76RL01830. This work was sponsored by the DOE- EERE, Vehicle Technology under project titled “Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints” partnership of Worcester Polytechnic Institute, Oak Ridge National Lab and Magna. We are thankful to Daniel Graff to assist during welding; Anthony Guzman for metallographic preparation; Tim Roosendaal, Ethan Nickerson, and Robert Seffens for mechanical testing and DIC analysis; and Joshua Silverstein for SEM characterization. The authors appreciate material support provided by Tim Skszek, Magna.
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Das, H., Upadhyay, P., Kulkarni, S.S., Choi, W. (2021). Dissimilar Joining of ZEK100 and AA6022 for Automotive Application. In: Hovanski, Y., Sato, Y., Upadhyay, P., Naumov, A.A., Kumar, N. (eds) Friction Stir Welding and Processing XI . The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-65265-4_11
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