Brazability of dissimilar metals tungsten inert gas butt welding–brazing between aluminum alloy and stainless steel with Al–Cu filler metal

Dissimilar metals tungsten inert gas butt welding–brazing between 5A06 aluminum alloy and SUS321 stainless steel was carried out using Al–Cu6 filler metal and non-corrosive flux. A thin intermetallic compound layer has formed in welded seam/steel interface and the average thickness of the whole layer is 3–5 μm, which is less than the limited value of 10 μm. The intermetallic compound layer consists of Fe₄Al₁₃ phase and at the bottom Sn deposits in the molten flux layer and diffuses into steel matrix to form the grain boundary filter layer, which is the weak zone of the butt joint. The average microhardness of the layer is 644.7 HV, compared with 104.5 HV in welded seam and 200 HV in steel matrix. The tensile strength of butt joint reaches 172.5 MPa and the crack initiates from the IMC layer at the bottom of the joint and derives into welded seam at the upper part of the joint. The present joint in this study has higher level than those with coated layer.     

Effect of Al foils interlayer on microstructures and mechanical properties of Mg–Al butt joints welded by gas tungsten arc welding filling with Zn filler metal

Gas tungsten arc butt welding of Mg–Al filling with Zn filler metal without and with Al foils in different thicknesses was carried out. Additional Al element was introduced into the fusion zone to accurately modulate microstructure and composition of the welding seam. Microstructures and mechanical properties of the welded joints were examined. Results show that the addition of appropriate quantity of Al element increases the content of Al-based solid solution in the fusion zone near the Mg base metal. The solid solution can eliminate the stress concentration and hinder crack propagation, so the tensile strengths of the joints are improved. However, the immoderate quantity of Al element will lead to the formation of partially Al-rich zones and deteriorate the mechanical property of the joints.     

Interface microstructure and mechanical properties of arc spot welding Mg–steel dissimilar joint with Cu interlayer

A novel technology was developed for the arc spot welding of AZ31 Mg alloy to Q235 steel with Cu as interlayer. The mechanisms of bonding dissimilar materials were investigated using mechanical and metallurgical examinations. Results show that the joining of Mg alloy to steel with Cu involved two bonding mechanisms: weld-brazing by the Cu transition layer at the interface edge and bonding by a micron-scale composite transition layer of Al₃Cu₄Fe₃ and Fe₄Cu₃ intermetallic phases at the interface center. The additional reaction of Cu increased the reaction temperature and composition ranges at the interface. It also elicited a bridge effect that improved the weldability of Mg alloy and steel by new formed phases.     

Joint properties of dissimilar Al6061-T6 aluminum alloy/Ti–6%Al–4%V titanium alloy by gas tungsten arc welding assisted hybrid friction stir welding

Hybrid friction stir butt welding of Al6061-T6 aluminum alloy plate to Ti–6%Al–4%V titanium alloy plate with satisfactory acceptable joint strength was successfully achieved using preceding gas tungsten arc welding (GTAW) preheating heat source of the Ti alloy plate surface. Hybrid friction stir welding (HFSW) joints were welded completely without any unwelded zone resulting from smooth material flow by equally distributed temperature both in Al alloy side and Ti alloy side using GTAW assistance for preheating the Ti alloy plate unlike friction stir welding (FSW) joints. The ultimate tensile strength was approximately 91% in HFSW welds by that of the Al alloy base metal, which was 24% higher than that of FSW welds without GTAW under same welding condition. Notably, it was found that elongation in HFSW welds increased significantly compared with that of FSW welds, which resulted in improved joint strength. The ductile fracture was the main fracture mode in tensile test of HFSW welds.     

The preparation and mechanical properties of carbon–carbon/lithium–aluminum–silicate composite joints

Silica carbide modified carbon cloth laminated C–C composites have been successfully joined to lithium–aluminum–silicate (LAS) glass–ceramics using magnesium–aluminum–silicate (MAS) glass–ceramics as interlayer by vacuum hot-press technique. The microstructure, mechanical properties and fracture mechanism of C–C/LAS composite joints were investigated. SiC coating modified the wettability between C–C composites and LAS glass–ceramics. Three continuous and homogenous interfaces (i.e. C–C/SiC, SiC/MAS and MAS/LAS) were formed by element interdiffusions and chemical reactions, which lead to a smooth transition from C–C composites to LAS glass–ceramics. The C–C/LAS joints have superior flexural property with a quasi-ductile behavior. The average flexural strength of C–C/LAS joints can be up to 140.26 MPa and 160.02 MPa at 25 °C and 800 °C, respectively. The average shear strength of C–C/LAS joints achieves 21.01 MPa and the joints are apt to fracture along the SiC/MAS interface. The high retention of mechanical properties at 800 °C makes the joints to be potentially used in a broad temperature range as structural components.     

The effect of gas tungsten arc welding and pulsed-gas tungsten arc welding processes’ parameters on the heat affected zone-softening behavior of strain-hardened Al–6.7Mg alloy

The heat affected zone (HAZ) softening behavior of strain-hardened Al–6.7Mg alloy welded by gas tungsten arc welding (GTAW) process was investigated. Increasing the heat input during welding led to formation of a wider HAZ. Moreover, the size of the precipitates was increased at higher heat inputs. Consequently, by increasing the heat input, lower strength was obtained for the welding joints. At the second stage of the study, pulsed-GTAW (PGTAW) process was employed to improve the strength of the joints. It was observed that the overall strength of the welding joints was improved and the fracture during tensile test was moved from the HAZ to the fusion zone. Moreover, the effect of duration ratio and pulse frequency was studied. For the current study, the duration ratio did not have a significant effect on the strength and microstructure of the weld, but increasing the frequency led to higher strength of the weld and finer microstructure.     

Guidelines for establishment of correlations between mechanical properties and microstructure in Al–Si alloys

Abstract

This paper reports an analysis of the accuracy and sensitivity of ultimate tensile strength and strain to failure to changes in microstructure constituents in Al–Si alloys ranging from 7 to 18%Si. The influence of amount of constituents, namely dendrites, eutectic, silicon particles and intermetallics as well as their geometrical features, namely secondary dendrite arm spacing, silicon eutectic thickness and intermetallics thickness on both ultimate tensile strength and strain to failure is evaluated. This study provides information that will be useful in the establishment of robust correlations between mechanical properties and metallurgical features, since they are highly dependent on their sensitivity and accuracy.     

Laser–arc hybrid welding of high-strength steel and aluminum alloy joints with brass filler

The laser–tungsten inert gas hybrid welding method was adopted to realize the welding process between Q460 high-strength steel and 6061 aluminum alloy. The influence of the dual heat source on the mechanical properties and microstructure of the welded joints are discussed. In addition, the effects of including a copper–zinc interlayer on the microstructure, elemental distribution, and mechanical properties of welded joints are also studied. The results show that the mechanical properties of the welded joints are influenced by the relative heat inputs of the two heat sources and the Cu-Zn interlayer. The braze welded joint fabricated without a Cu-Zn interlayer fractured at an Al-Fe intermetallic compound (IMC) layer formed at the interface, whereas the braze welded joint fabricated with a Cu-Zn interlayer fractured at an Al-Cu IMC layer formed at the interface. Comparisons show that the maximum tensile shear load of the brazed welded joint with the Cu-Zn interlayer was increased by about 20% relative to that formed without the interlayer. The formation of Al-Fe IMC layer in the deep penetration joint was inhibited by the combined effect of the dual heating sources and the Cu-Zn interlayer.     

Effects of friction stir welding on microstructure and mechanical properties of extruded secondary aluminum 6061 alloy

Experiments were carried out to determine the effects of friction stir welding on microstructure and properties of recycled Aluminum 6061 alloy, whose alloy content varied from that of primary alloy. The alloy was processed at tool speed and feed ranges of 530 rev/min–1320 rev/min and 40 mm/min–100 mm/min respectively. Microstructure examination; tensile test and Vickers microhardness evaluation were carried out. Microstructure of the alloy was in four zones including: base metal, heat affected zone, thermo-mechanically affected zone and stirred zone. Average grain size of unprocessed material was 93 μm. Processing the alloy at 530 rev/min and 100 mm/min resulted in grains of average size 93 μm, 183 μm and 7 μm; in base metal, heat affected zone and stirred zone respectively. Tensile failure occurred in heat affected zone; that was exposed to high heat. The alloy hardness decreased to a minimum in heat affected zone, followed by a brief rise in thermo-mechanically affected zone, to another maximum in stirred zone. Processed zone hardness was inversely proportional to tool speed and directly proportional to feed rate. Increase in the speed and decrease in feed, increased heat which deteriorated the properties.     

Microstructure and mechanical properties of laser welded joints between 2198/2060 Al–Li alloys

Dissimilar Al–Li alloys (2198 and 2060) were laser welded without the addition of filler material. The effects of welding parameters on the formation of the welded joints, microstructure evolution, solute segregation, porosity and their relationships with the mechanical properties of the joint were investigated. It was found that reducing the weld heat input can effectively prevent grain coarsening, while decreasing porosity and reducing the tendency for hot cracking, thereby enhancing the properties of the joint. The dissolution of precipitates such as the T1 phase and θ′ phase in the base metal, and the variations in Cu and Mg content between grain interiors and boundaries, resulted from solute segregation during welding, leading to reductions in the strength of the weld.     

Effect of welding parameters on microstructure and mechanical properties of friction stir welded joints of a super high strength Al–Zn–Mg–Cu aluminum alloy

Samples made of a super high strength aluminum alloy with high Zn content were friction stir welded with rotation rates of 350–950 rpm and welding speeds of 50–150 mm/min. The effect of welding parameters on the microstructure and mechanical properties was investigated. It was observed that the grain size of the nugget zones decreased with the increasing welding speed or the decreasing tool rotation rate. Most of the strengthening precipitates in the nugget zone were dissolved back and the intragranular and grain boundary precipitates in the heat affected zone coarsened significantly. The greatest ultimate tensile strength of 484 MPa and largest elongation of 9.4 were obtained at 350 rpm−100 mm/min and 350 rpm−50 mm/min, respectively. The ultimate tensile strength and elongation deteriorated drastically when rotation rate increased from 350 to 950 rpm at a constant welding speed of 100 mm/min.     

Effects of Nb content in Ti–Ni–Nb brazing alloys on the microstructure and mechanical properties of Ti–22Al–25Nb alloy brazed joints

Vacuum brazing was successfully used to join Ti–22Al–25Nb alloy using Ti–Ni–Nb brazing alloys prepared by arc-melting. The influence of Nb content in the Ti–Ni–Nb brazing alloys on the interfacial microstructure and mechanical properties of the brazed joints was investigated. The results showed that the interfacial microstructure of brazed joint consisted of B2, O, ?3, and Ti2 Ni phase, while the width of brazing seams varied at different Nb contents. The room temperature shear strength reached359 MPa when the joints were brazed with eutectic Ti40Ni40Nb20 alloy at 1180?C for 20 min, and it was321, 308 and 256 MPa at 500, 650 and 800?C, respectively. Cracks primarily initiated and propagated in ?3compounds, and partially traversed B2+O region. Moreover, the fracture surface displayed typical ductile dimples when cracks propagated through B2+O region, which was favorable for the mechanical properties of the brazed joint.     

Improving interfacial reaction nonhomogeneity during laser welding–brazing aluminum to titanium

Heterogeneous interfacial reactions were easily found along the Ti/Al interface due to high temperature gradient during laser welding–brazing of Ti/Al dissimilar alloys. To improve the nonhomogeneity, relative uniform energy distribution of laser beam and appropriate groove were attempted. The effects of these attempts on the nonhomogeneity of interfacial reactions were investigated by finite element method (FEM) numerical simulation and experimental validation. The results indicate that the V-shaped groove can make the interface roughly parallel to the isotherm of the temperature field. Moreover, the rectangular spot laser can further improve homogenization of the interfacial reaction along the interface in comparison with circular spot laser. Tensile test results show that the combination of rectangular spot laser welding–brazing and V-shaped groove can effectively control the fracture of Ti/Al joints in the seam in a wide processing parameters window, and the average tensile strength reaches 278 MPa.     

The microstructure and mechanical properties of as-cast Mg–4Y/Nd–2Zn alloys

Optical microscopy, scanning electron microscopy, X-ray diffraction and tensile testing were performed to investigate the microstructure and mechanical properties of as-cast Mg–4Y/Nd–2Zn alloys. The results show that the secondary dendritic arm spacing for the Mg–4Y–2Zn alloy is smaller than that for the Mg–4Nd–2Zn alloy, and that X-Mg₁₂YZn or W-Mg₃Zn₃Nd₂ form in Mg–4Y/Nd–2Zn alloys. The lamellar X phase distributes at the grain boundary, pointing into the grains, whereas the rod-like W phase preferentially segregates at the triangle junction of the grain boundary. The greater grain boundary strengthening effect and the smaller fragmentation effect of the brittle eutectic phases leads to the as-cast Mg–4Y–2Zn alloy having better comprehensive mechanical properties. The fracture mechanism for as-cast Mg–4Y/Nd–2Zn alloys is quasi-cleavage fracture.     

The effects of Mg amount on the microstructure and mechanical properties of Al–Si–Mg alloys

In this study, the effects of magnesium (Mg) addition to A356 aluminum alloy at different amounts on the microstructure and mechanical properties of this alloy were examined. For the experimental studies, three different alloys (0.43, 0.67 and 0.86 wt%) having various amounts of Mg were prepared through casting process in the form of plates. The plates were homogenized and cooled in the furnace. All the samples were treated with aging process (T6) and then tensile samples were prepared from the homogenized samples. The samples treated with T6 process were characterized by optical microscopy, laser confocal microscopy, Scanning Electron Microscope (SEM), Energy Dispersive Spectrometer (EDS) and X-Ray Diffraction (XRD) examinations as well as hardness measurements and tensile tests. The phases which were formed in the microstructures for different amounts of Mg were examined. It was observed that iron-rich intermetallic compounds were also formed in addition to the phases resulting from the aging process. Fe-rich intermetallic compounds, observed from the fracture surfaces, were found to reduce the tensile strength the alloy. The results also indicate that the tensile strength and hardness of the alloy increase with increasing Mg amount.     

The relationship between the electrical and mechanical properties of polymer–nanotube nanocomposites and their microstructure

A range of polymer–nanotube nanocomposites were produced using different processing routes. Both polymer-grafted and as-grown nanotubes were used and latex and polystyrene matrices investigated. The microstructures of the nanocomposites were studied, mainly by electron microscopy, in terms of the dispersion state of the nanotubes and the polymer–nanotube interface. The mechanical and electrical properties of the composites were also measured. The relationship between the microstructures observed and the resulting physical properties are discussed. It is found that composites with apparently similar microstructures can exhibit similar mechanical properties but very different electrical behaviours. Moreover, the nanocomposites produced using polymer-grafted nanotubes exhibit a clear improvement of the stress at large deformation. Thus, from our results, it appears that the mechanical and electrical properties do not necessarily depend on the same microstructural parameters. However it is still a challenge to simultaneously improve both physical properties.     

Laser–tungsten inert gas hybrid welding of dissimilar AZ based magnesium alloys

Abstract

The microstructure and mechanical properties of dissimilar AZ based magnesium alloys subjected to laser–tungsten inert gas (TIG) hybrid welding have been investigated. The results show that magnesium alloys can be readily welded as dissimilar joints using this process. The microstructure of the dissimilar magnesium alloy joints is composed of primary α phase (Mg) and β phase (Mg₁₇Al₁₂), based on electron probe microanalysis (EPMA) and X-ray diffraction (XRD) data. In addition, the tensile strength of AZ31B–AZ61 and –AZ91 joints is equal to that of AZ31B base metal. It has also been found that the presence of β phase has a severe influence on the tensile strength and mirohardness of dissimilar magnesium alloy joints.     

Microstructure and mechanical properties of molybdenum–iron–boron–chromium cladding using argon arc welding

The molybdenum–iron–boron–chromium claddings with different Mo/B atomic ratios were produced on Q235 steel using argon arc welding. The microstructure and crystalline phases were studied by optical microscopy, scanning electron microscopy and XRD. In addition, the formation mechanism of hard phase was investigated by thermodynamic calculations and phase diagrams. The results showed that the claddings were composed of the Mo₂FeB₂, M₃B₂ (M: Mo, Fe and Cr) hard phases and σ-FeMoCr solid solution. In addition, calculated results revealed that the M₃B₂, MB and σ-FeMoCr were successively precipitated from the melting pool. Moreover, the maximum microhardness value of the cladding was about 1600 HV_0.5. Wearing test indicated that claddings of lower Mo/B ratios have better wear resistance.     

Effect of Si content on microstructure and mechanical properties of Al–Si–Mg alloys

Microstructure and mechanical properties of as-cast and as-extruded Al–Si–Mg alloys with different Si content are investigated by tensile test, microstructure observation. High density of Si particles in the Al alloys can induce dynamic recrystallization during hot extrusion and it becomes more matured with an increase in the density of Si particles. The tensile strength of as-cast and as-extruded alloys can be improved with the increase of Si content and hot extrusion make the elongation of alloys increase dramatically. Considerable grain refining effect caused by recrystallization occurred during hot extrusion of S2 (equivalently commercial A356 alloy) and S3 (near eutectic alloy) alloys plays an important role in the improvement of elongation. A good combination of strength and elongation for the as-extruded S3 alloy indicates that near eutectic Al–Si alloys can be hot-extruded to produce aluminum profiles with high performance.     

Effect of aluminium on the microstructure and mechanical properties of as-cast magnesium–manganese alloys

In this paper, the effect of aluminium on microstructure and mechanical properties of as-cast magnesium–manganese alloy has been investigated by means of X-ray diffraction, optical microscopy and scanning electron microscopy. The results reveal that various Al–Mn intermetallic compounds form with an increase of Al content. As a result, microstructure of AM11 alloy has been effectively refined due to the formation of Al₈Mn₅ phase along the grain boundary, while Al addition is explained as the main reason on refining the microstructure of AM91 alloy due to its higher grain growth restriction factor value of ～4.32. The tensile yield strength (TYS) has been improved steadily from 27.4 to 122.9?MPa with increasing Al content, because of the combined effects of grain boundary strengthening, solid solution strengthening and precipitation hardening behaviours.