Journal
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
Volume 556, Issue -, Pages 31-42Publisher
ELSEVIER SCIENCE SA
DOI: 10.1016/j.msea.2012.06.055
Keywords
Intermetallic compounds; Al12Mg17; Al3Mg2; Reaction kinetics; Ultrasonic welding
Categories
Funding
- EPSRC through LATEST2, Light Alloys towards Environmentally Sustainable Transport [EP/G022402/1]
- Friction Joining-Low Energy Manufacturing for Hybrid Structures in Fuel Efficient Transport Applications [EP/G022402/1.JLR]
- Engineering and Physical Sciences Research Council [EP/H020047/1, EP/G022402/1] Funding Source: researchfish
- EPSRC [EP/G022402/1, EP/H020047/1] Funding Source: UKRI
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High power ultrasonic spot welding (USW) is a low heat input solid-state joining process that may offer a solution for welding difficult dissimilar-material couples, like magnesium (Mg) to aluminium (Al) for automotive body applications. However, the high strain rate dynamic deformation in USW has been claimed to accelerate inter-diffusion rates in dissimilar joints. The interfacial reaction between Al, AA6111, and Mg AZ31 alloys has been studied as a function of welding energy. For the optimum welding condition of 600J (0.4 s) the reaction layer thickness was already similar to 5 mu m thick. Intermetallic reaction centres were found to nucleate within microwelds at the interface at very short welding times and spread and grow rapidly to form a continuous layer, composed of two sub-layers of Al12Mg17 and Al3Mg2. Interface liquation was also found for longer welding times at temperatures below the recognised lowest eutectic reaction temperature in the Al-Mg binary system. Modelling has been used to show that the solid state reaction kinetics were over twice the rate expected from parabolic growth predictions made using rate constants obtained under static test conditions. The reasons for this discrepancy and the depressed melting reaction are discussed. (c) 2012 Elsevier B.V. All rights reserved.
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