Formation and thermal stability of new Zr–Cu-based bulk glassy alloys with unusual glass-forming ability

The simultaneous addition of Al and Ag to Zr–Cu binary alloys increased in the stabilization of supercooled liquid, the reduced glass transition temperature and γ value, leading to greatly enhance the glass-forming ability (GFA). The Zr–Cu–Ag–Al glassy alloy samples with diameters above 15 mm were obtained in the wide composition range of 42–50 at% Zr, 32–42 at% Cu, 5–10 at% Ag, and 5–12 at% Al. The best GFA was obtained for Zr₄₈Cu₃₆Ag₈Al₈ alloy, and the glassy samples with diameters up to 25 mm were fabricated by an injection copper mold casting. The Zr₄₈Cu₃₆Ag₈Al₈ glassy alloy exhibited high tensile and compressive fracture strength of over 1800 MPa.     

Electrochemical properties and surface analysis of Cu–Zr–Ag–Al–Nb bulk metallic glasses

The electrochemical properties and surface characteristics of Cu–Zr–Ag–Al–Nb bulk metallic glasses (BMGs) were investigated. The alloys exhibit excellent corrosion resistance after immersion in 1N H₂SO₄ and 1N NaOH. The corrosion rates of the alloys in chloride-ion-containing solutions significantly decrease by alloying with Nb element. The formation of Zr- and Nb-enriched surface films could be responsible for the high corrosion resistance.     

Microstructure identification of devitrified Cu–Ti–Zr–Ni bulk amorphous alloy

The microstructures of devitrified Cu–Ti–Zr–Ni bulk amorphous alloy were identified by X-ray diffractometry (XRD) and transmission electron microscope (TEM). XRD and TEM examinations show that the deep eutectic structures of the tested alloy consist of CuTi₂–Cu₁₀Zr₇, Cu₃Ti–CuZr, Cu₃Ti–Cu₁₀Zr₇–CuZr low-order eutectics. Moreover, short-range ordering clusters in the melt with configuration similar to that of Cu₁₀Zr₇ compound may contribute to the glass forming ability of bulk amorphous Cu–Ti–Zr–Ni alloy.     

Low-temperature brazing of titanium by the application of a Zr–Ti–Ni–Cu–Bebulk metallic glass (BMG) alloy as a filler

Titanium (Ti) was successfully brazed at low temperatures below 800 °C by employing a Zr_41.2Ti_13.8Ni_10.0Cu_12.5Be_22.5 (at.%) bulk metallic glass (BMG) alloy as a filler. Through the use of this alloy filler, the detrimental segregation of Zr–Cu–Ni filler elements was completely eliminated by heating to well below 800 °C, so the resultant joint was quite homogeneous with a coarse acicular structure. The disappearance of the Zr–Cu–Ni segregated region was rate-controlled by the diffusion of the filler elements in the Ti base metal. Remarkably, the mechanical property and corrosion resistance of the homogeneous joint brazed at 800 °C for 10 min were mostly comparable to those of bulk Ti.     

Microstructure and Mechanical Properties of Dissimilar Double-Side Friction Stir Welds Between Medium-Thick 6061-T6 Aluminum and Pure Copper Plates

It is difficult to achieve Al/Cu dissimilar welds with good mechanical properties for medium-thick plates due to the inherent high heat generation rate at the shoulder-workpiece contact interface in conventional friction stir welding. Thus, double-side friction stir welding is innovatively applied to join 12-mm medium-thick 6061-T6 aluminum alloy and pure copper dissimilar plates, and the effect of welding speeds on the joint microstructure and mechanical properties of Al/Cu welds is systematically analyzed. It reveals that a sound Al/Cu joint without macroscopic defects can be achieved when the welding speed is lower than 180 mm/min, while a nonuniform relatively thick intermetallic compound (IMC) layer is formed at the Al/Cu interface, resulting in lots of local microcracks within the first-pass weld under the plunging force of the tool during friction stir welding of the second-pass, and seriously deteriorates the mechanical properties of the joint. With the increase of welding speed to more than 300 mm/min void defects appear in the joint, but the joint properties are still better than the welds performed at low welding speed conditions since a continuous uniform thin IMCs layer is formed at the Al/Cu interface. The maximum tensile strength and elongation of Al/Cu weld are, respectively, 135.11 MPa and 6.06%, which is achieved at the welding speed of 400 mm/min. In addition, due to the influence of welding distortion of the first-pass weld, the second-pass weld is more prone to form void defects than the first-pass weld when the same plunge depth is applied on both sides. The double-side friction stir welding is proved to be a good method for dissimilar welding of medium-thick Al/Cu plates.     

Effect of hot dip aluminising on interfacial microstructure and mechanical properties of Ti/Al joint by TIG arc welding brazing

Abstract

The joint of Al 5A06 and aluminised Ti–6Al–4V dissimilar alloys was achieved by means of tungsten inert gas arc welding brazing. The effect of aluminized coating on the spreading behaviour of filler metal on Ti substrate was studied. The spreadability of liquid filler metal on the Ti substrate was enhanced obviously due to the presence of aluminised coating. The interfacial reaction layer was characterised by a uniform lamellar layer of TiAl₃ intermetallic, with a thickness of 1 μm. Sound joints with well appearance were obtained, and the optimised tensile strength of the joint reached 216 MPa. The failure initiated from the interfacial layer at the root face and then propagated within the weld seam at the upper part of the joint. Capable welding parameters were broadened by the presence of aluminised coating for dissimilar metal joining of Ti/Al.     

Concept of chemical short range order domain and the glass forming ability in multicomponent liquid

The concept of multicomponent chemical short-range order (MCSRO) domain is systematically developed by the experimental investigation of Zr–Ti–Cu–Ni–Al bulk metallic glass (BMG) and thermodynamic modeling and calculation. The existence of MCSRO domains in Zr-based BMG is verified by the observations of high-resolution transmission electron microscopy (HRTEM) images and the analysis of nano-beam electron diffraction patterns. The size of the nano-beam used in this work is 0.5 nm in diameter. Thermodynamic evaluation of the melt composed of multiple-MCSRO domains and glass-forming ability (GFA) based on the concept of MCSRO domains has also been conducted. It is indicated that the thermodynamic calculation of the GFA based on MCSRO model is consistent with the experimental data of crystallization activation energy and glass transition temperature for Ni-Zr and Zr-Cu binary alloys, and with supercooled liquid region (ΔT_x) for Zr–Ni–Al ternary alloy. The existence of MCSRO domain lowers the free energy of the melt (ΔG_MCSRO), resulting in a large undercooling and a larger energy barrier to the nucleation of a critical crystalline nucleus. Large ΔG_MCSRO, low melting point as well as co-existence of multiple MCSRO domains are valid criterion for the valuation of GFA.     

铝/钢异质金属搅拌摩擦焊技术研究进展

铝/钢异质金属复合结构具有轻质节能、降低成本、可以满足不同的工作条件等特点,在航空航天、船舶制造等领域的应用日益受到重视。由于铝和钢的物理化学性质存在巨大差异,铝和钢的连接成为焊接领域的难点问题。搅拌摩擦焊作为一种固相连接方法,具有热输入低、高温停留时间短、焊接变形小等特点,对克服铝/钢异质金属性能差异带来的焊接困难具有优势,已成为铝/钢异质金属焊接的研究热点。综述了铝/钢异质金属搅拌摩擦焊国内外研究现状,主要涉及搅拌头材料选择与结构设计、焊缝成形、焊接工艺窗口、力学性能、接头冶金结合、连接机制以及外源辅助搅拌摩擦焊新技术,可以为铝/钢异质金属结构的轻量化设计提供新思路,最后对其发展趋势进行了展望。     

The corrosion behavior of Cu–Al and Cu–Al–Be shape-memory alloys in 0.5 M H2SO4 solution

The corrosion behavior of Cu–Al and Cu–Al–Be (0.55–1.0 wt%) shape-memory alloys in 0.5 M H₂SO₄ solution at 25 °C was studied by means of anodic polarization, cyclic voltammetry, and alternative current impedance measurements. The results of anodic polarization test show that anodic dissolution rates of alloys decreased slightly with increasing the concentrations of aluminum or beryllium. Severe intergranular corrosion of Cu–Al alloy was observed after alternative current impedance measurement performed at the anodic potential of 0.6 V. However, the addition of a small amount of beryllium was effective to prevent the intergranular corrosion. The effect of beryllium addition on the prevention of intergranular corrosion is possibly attributed to the diffusion of beryllium atoms into grain boundaries, which in turn deactivates the grain boundaries.     

Formation and properties of the Zr75−xAlxNi10Cu10Ti5 bulk metallic glasses

Zr-based bulk metallic glasses (BMGs) exhibit interesting mechanical properties since they combine high fracture stress, elastic strain (up to 2%), significant fracture toughness and good corrosion resistance. Quaternary systems with general composition Zr–Ni–Cu–Ti show wide composition ranges in which BMG can be obtained. The addition of the another element to the quaternary alloys often increases the glass forming ability (GFA). The aim of this work was to study the influence of aluminium content on the GFA and on the mechanical properties of the Zr–Ni–Cu–Ti alloys. Multicomponent Zr_75−xAl_xNi₁₀Cu₁₀Ti₅ (x = 15, 20 at%) alloys were produced by melt spinning method obtaining ribbons, and by casting technique into a copper mould, manufacturing rod shape samples with maximum diameter of 2 mm. Supercooled liquid region depends on chemical composition and exceeds 45 °C. Vickers microhardness of studied alloys is comparable to the highest ones for other Zr-based BMG.     

Mechanisms of joining aluminium A6061-T6 and titanium Ti–6Al–4V alloys by cold metal transfer technology

Abstract

Cold metal transfer (CMT) welding–brazing joining of Ti6Al4V and Al A6061-T6 was carried out using AlSi₅ wire. The joining mechanisms and mechanical properties of the joints were identified and characterised by scanning electron microscope, energy dispersive spectroscopy and tensile–shear tests. Desired CMT joints with satisfied weld appearances and mechanical properties were achieved by overlapping Ti on the top of Al. The joints had dual characteristics of a welding joint on the aluminium side and a brazing joint on the titanium side. Three brazing interfaces were formed for the joint, which increased the strength of the joint. An intermetallic compound layer was formed at the brazing interface, which included Ti₃Al, TiAl and TiAl₃. Two different fracture modes were also observed: one fractured at the welding/brazing interface and weld metal and the other at the Al heat affected zone (HAZ). Clearly, the joints fractured at the Al HAZ had higher tensile strength than those fractured at the welding/brazing interface and weld metal.     

Materials flow and phase transformation in friction stir welding of Al 6013/Mg

Material flow and phase transformation were studied at the interface of dissimilar joint between Al 6013 and Mg, produced by stir friction welding (FSW) experiments. Defect-free weld was obtained when aluminum and magnesium were placed in the advancing side and retreating side respectively and the tool was placed 1 mm off the weld centerline into the aluminum side. In order to understand the material flow during FSW, steel shots were implanted as indexes into the welding path. After welding, using X-ray images, secondary positions of the steel shots were evaluated. It was revealed that steel shots implanted in advancing side were penetrated from the advancing side into the retreating side, whereas the shots implanted in the retreating side remained in the retreating side, without penetrating into the advancing side. The welded specimens were also heat treated. The effects of heat treatment on the mechanical properties of the welds and the formation of new intermetallic layers were investigated. Two intermetallic compounds, Al₃Mg₂ and Al₁₂Mg₁₇, were formed sequentially at Al6013/Mg interface.     

Refill Friction Stir Spot Welding of Similar and Dissimilar Alloys:A Review

Refi ll friction stir spot welding, also known as friction spot welding(FSpW), is a solid-state welding process suitable for spot joining of lightweight materials. Through the eff orts of improving joint quality for similar and dissimilar materials, for example, aluminum and magnesium, this joining technology is well developed. The joining mechanism and process characteristics of FSpW have been widely studied. However, the application of FSpW in industry has not been entirely successful. In this review article, the research of similar and dissimilar material joints, such as, Al/Cu, Al/Ti, Al/Mg and Al/Steel, is summarized. The microstructural features and mechanical properties of the joints, welding tool and the application development are discussed in detail.     

Interface morphology and microstructure of high-power ultrasonic spot welded Mg/Al dissimilar joint

High-power ultrasonic welding technology, which has the excellent characteristics of low-energy input and high efficiency, can effectively shorten the welding time, reduce the formation of intermetallic compounds (IMCs), and improve the strength of Mg/Al dissimilar welded joints in the future manufacturing industry. Mg/Al dissimilar metal ultrasonic welded joints with favourable mechanical properties were obtained through reasonable selection of sonotrode patterns and optimisation of welding parameters. The connection mechanisms of joints were discussed based on the analysis of weld interface morphology, microstructure evolution, and the composition and distribution of Mg–Al IMCs that varied with welding energy. The mechanical interlocking phenomenon and discontinuously distributed Mg₁₇Al₁₂ with low thickness were observed at the weld interface, which helped to improve the joint performance.     

Strong bonding of infrared brazed α2-Ti3Al and Ti–6Al–4V using Ti–Cu–Ni fillers

Infrared dissimilar brazing of α₂-Ti₃Al and Ti–6Al–4V using Ti–15Cu–25Ni and Ti–15Cu–15Ni filler metals has been performed in this study. The brazed joint consists primarily of Ti-rich and Ti₂Ni phases, and there is no interfacial phase among the braze alloy, α₂-Ti₃Al and Ti–6Al–4V substrates. The existence of the Ti₂Ni intermetallic compound is detrimental to the bonding strength of the joint. The amount of Ti₂Ni decreases with increasing brazing temperature and/or time due to the depletion of Ni content from the braze alloy into the Ti–6Al–4V substrate during brazing. The shear strength of the brazed joint free of the blocky Ti₂Ni phase is comparable with that of the α₂-Ti₃Al substrate, and strong bonding can thus be obtained.     

Microstructure evolution in refill friction stir spot weld of a dissimilar Al–Mg alloy to Zn-coated steel

In the present study, dissimilar welds of an Al–Mg–Mn alloy and a Zn-coated high-strength low-alloy steel were welded by refill friction stir spot welding. The maximum shear load recorded was approximately 7.8?kN, obtained from the weld produced with a 1600?rev min^?1 tool rotational speed. Microstructural analyses showed the formation of a solid–liquid structure of an Al solid solution in Mg–Al-rich Zn liquid, which gives rise to the formation of Zn-rich Al region and microfissuring in some regions during welding. Exposure of steel surface to Mg–Al-rich Zn liquid led to the formation of Fe₂Al₅ and Fe₄Al₁₃ intermetallics. The presence of defective Zn-rich Al regions and Fe–Al intermetallics at the faying surface affects the weld strength.     

Properties of as welded and heat treated pure titanium–7075 Al–Zn–Mg alloy friction weld joints

Abstract

The effects of joining conditions and an age hardening post­weld heat treatment (PWHT) at 120°C for 24 h on the tensile strength and metallurgical properties of dissimilar friction joints between pure titanium and age strengthened 7075 Al–Zn–Mg alloy were investigated. Highest strength was achieved using intermediate friction pressure (150 MPa), short friction time (0.5 s), and high upsetting (forging) pressure (400 MPa). The joint tensile strength decreased when the joint diameter was increased from 8 to 16 mm. The joint tensile strength of as welded (AW) dissimilar joints was similar to that of PWHT joints with diameters of 8, 12, and 16 mm. Detailed TEM confirmed that there was a negligible difference in the thickness of the intermetallic layer formed at the dissimilar joint interface for AW and PWHT joints. While the intermetallic phases formed at the joint interface comprised Al₃Ti, τ (Ti₂Mg₃Al₁₈), and Al in AW joints, they consisted of Al+τ or Mg₂Al₃+τ+Al in PWHT joints. Softened regions were generated in 7075 base material immediately next to the interface in AW joints. Post­weld heat treatment increased the hardness of the softened region almost to that of as received 7075–T6 base material in 12 and 16 mm diameter joints. In contrast, the hardness of the softened region in 8 mm diameter joints could not be recovered to that of the as received material. This was a result of overaging and coarse precipitates in the softened region produced during the friction welding operation.     

镁铝异种金属激光-TIG复合热源焊焊接性分析

采用激光-TIG复合热源和TIG焊接异种金属镁和铝，利用X射线衍射仪、金相显微镜和扫描电镜研究镁和铝焊接接头的微观组织、元素分布。结果表明，TIG焊接镁和铝形成连续的金属间化合物层，导致镁和铝接触的界面开裂，不能实现有效的连接。激光-TIG复合热源由于其焊接速度高和对熔池的快速搅拌作用，使镁和铝形成的金属间化合物由连续的层状变成弥散的状态，改善了异种金属镁和铝的焊接性。镁和铝激光-TIG复合热源焊接的焊缝成形均匀，美观。     

Electrochemical corrosion behaviour of stir zone of friction stir welded dissimilar joints of AA6061 aluminium–AZ31B magnesium alloys

Joining of dissimilar metals will offer many advantages in transportation sectors such as fuel consumption, weight reduction and emission reduction. However, joining of aluminium (Al) alloys with magnesium (Mg) alloys by fusion welding process is very complicated. Friction stir welding (FSW) is a feasible method to join these two dissimilar alloys. Mixing these two metals together in stir zone (SZ) leads to poor corrosion resistance. In this investigation, an attempt has been made to understand the corrosion resistance of SZ of FSWed dissimilar joints of AA6061 Al alloy and AZ31B Mg alloy. Potentiodynamic polarization test was conducted by varying chloride ion concentration, pH value of the NaCl solution and exposure time. The corroded surfaces were analyzed using optical microscopy, scanning electron microscopy and XRD techniques. Of these three factors investigated, exposure time is found to be the most significant factor to influence the corrosion behaviour of SZ of friction stir welded dissimilar joints of Al/Mg alloys.     

Property improvement of copper films with zirconium additive for ULSI interconnects

Thermal stability of Cu–Zr/Zr–Si/Si connect system was evaluated by a standard four-point probe (FPP) method, X-ray diffraction (XRD) and Auger electron spectroscopy (AES) analyses. And the Cu/Zr–Si/Si connect system was used as control experiment. XRD spectra for the Cu–Zr/Zr–Si/Si and Cu/Zr–Si/Si stacked films after annealing showed that the Cu–Zr/Zr–Si/Si specimen was stable up to 650 °C. However, the peaks of Cu silicide (Cu₃Si) appeared for Cu/Zr–Si/Si specimen after annealing at 650 °C. The formation of high resistivity Cu₃Si corresponding to the drastic increase in sheet resistance of copper film. The results observed by AES were consistent with those obtained from XRD measurements and demonstrated that Cu–Zr/Zr–Si/Si system had more thermal stability than that of the Cu/Zr–Si/Si system. The thermal stability of Cu–Zr/Zr–Si/Si specimen was obviously improved when Zr was introduced into Cu film.