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Effect of Tool Offset and Tool Rotational Speed on Enhancing Mechanical Property of Al/Mg Dissimilar FSW Joints

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Abstract

Friction stir welding (FSW) is a promising solid-state joining technique for producing effective welds between Al alloy and Mg alloy. However, previously reported Al/Mg dissimilar FSW joints generally have limited strength or barely any ductility with relatively high strength, which was blamed on the brittle intermetallics formed during welding. In this study, effective joints with comparably high strength (163 MPa) and large elongation (~6 pct) were obtained. Three crucial/weak zones were identified in the welds: (1) Al/Mg bottom interface (BI) zone that resulted from the insufficient materials’ intermixing and interdiffusion; (2) banded structure (BS) zone which contains intermetallic particles possibly formed by constitutional liquation; and (3) softened Al alloy to the retreating side (SAA-RS) zone due to the dissolution and coarsening of the strengthening precipitates. Three fracture modes observed in the tensile specimens perpendicular to the weld seam were found closely related to these zones. Their microstructure evolution with the change of tool rotational speed and tool offset was characterized and the consequent effect on the fracture mode alteration was studied. It turned out that enhancing the strengths of all these zones, but keeping the strength of the SAA lowest, is an effective way for enhancing ductility while keeping comparatively high strength in Al/Mg FSW joints. Also, suggestions for further improving the mechanical property of the Al/Mg dissimilar FSW joints were made accordingly for practical applications.

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  1. Color figures are presented in the on-line version of this article.

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Acknowledgments

This work was supported by the National Natural Science Foundation of China (Grant No. 51204108), the Shanghai Committee of Science and Technology (Grant No. 11ZR1418100), and the Scientific Research Foundation for the Returned Overseas Chinese Scholars, State Education Ministry.

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Author notes

  1. Zhiyuan Liang (Undergraduate Student and Graduate Student)

    Present address: Department of Mechanical Engineering, The University of Hong Kong, Pokfulam Road, Hong Kong

Authors and Affiliations

  1. School of Materials Science and Engineering, Shanghai Jiao Tong University, 800 Dongchuan Road, Shanghai, 200240, P.R. China

    Zhiyuan Liang (Undergraduate Student and Graduate Student), Ke Chen (Lecturer), Xiaona Wang (Graduate Student), Lanting Zhang (Professor) & Aidang Shan (Professor)

  2. Special Welding Technology Center, Shanghai Aerospace Equipments Manufacturer, Shanghai, 200245, P.R. China

    Junshan Yao (Vice General Engineer)

  3. Research Institute, Baoshan Iron & Steel Co., Ltd, Shanghai, 201900, P.R. China

    Qi Yang (Chief Researcher)

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  1. Zhiyuan Liang
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Correspondence to Ke Chen.

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Manuscript submitted June 29, 2012.

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Liang, Z., Chen, K., Wang, X. et al. Effect of Tool Offset and Tool Rotational Speed on Enhancing Mechanical Property of Al/Mg Dissimilar FSW Joints. Metall Mater Trans A 44, 3721–3731 (2013). https://doi.org/10.1007/s11661-013-1700-4

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