Enhanced strength-ductility synergy in a wire and arc additively manufactured Mg alloy via tuning interlayer dwell time

Strength-ductility trade-off is a common issue in Mg alloys. This work proposed that a synergistic enhancement of strength and ductility could be achieved through tuning interlayer dwell time(IDT) in the wire and arc additive manufacturing(WAAM) process of Mg alloy.The thermal couples were used to monitor the thermal history during the WAAM process. Additionally, the effect of different IDTs on the microstructure characteristics and resultant mechanical properties of WAAM-processed Mg alloy thin-wall were investigated. The results showed that the stable temperature of the thin-wall component could reach 290 ℃ at IDT=0s, indicating that the thermal accumulation effect was remarkable. Consequently, unimodal coarse grains with an average size of 39.6 μm were generated, and the resultant room-temperature tensile property was poor. With the IDT extended to 60s, the thermal input and thermal dissipation reached a balance, and the stable temperature was only 170 ℃, closing to the initial temperature of the substrate. A refined grain structure with bimodal size distribution was obtained. The remelting zone had fine grains with the size of 15.2 μm, while the arc zone owned coarse grains with the size of 24.5 μm.The alternatively distributed coarse and fine grains lead to the elimination of strength-ductility trade-off. The ultimate tensile strength and elongation of the samples at IDT=60s are increased by 20.6 and 75.0% of those samples at IDT=0s, respectively. The findings will facilitate the development of additive manufacturing processes for advanced Mg alloys.

TLP bonding of alumina ceramic and 5A05 aluminum alloy using Ag-Cu-Ti interlayer

In order to join alumina ceramic to 5A05 aluminum alloy and obtain the excellent airtightness of joints whose maximum service temperature is 623 K, transient liquid phase （TLP） bonding technique was ,investigated using Ag-Cu-Ti alloy as interlayer. The wetting experimental results confirm that Ti can react with alumina ceramic at 833 K by adding 2 wt.% Ti in Sn. But during bonding alumina ceramic and 5A05 aluminum alloy with Ag-Cu-Ti interlayer at 833 K, Ti preferentially reacts with Al and there is no reaction layer on alumina ceramic/Ag-Cu-Ti interface, which finally results in a poorly airtight joint.

Research on Interlayer Alloys for Transient Liquid Phase Diffusion Bonding of Single Crystal Nickel Base Superalloy DD6

Transient Liquid Phase Diffusion bonding (TLP bonding) is an effective method to achieve excellent joint of DD6, which is a new generation single crystal superalloy to manufacture aero-engine turbine blades. In this paper, the interlayer alloys for DD6 TLP bonding were designed. The alloy foils with thickness 40 μm ~ 60 μm, width 4 mm were prepared by using a single roller rapid solidification apparatus and the TLP bonding of DD6 was conducted. Then the joint microstructure and alloying elements diffusion behaviors were analyzed. The results indicate that microstructures of interlayer alloys prepared are fine and homogeneous, the melting point range of alloys from 1070°C to 1074°C and their melting temperature interval is merely 20°C, when the chemical composition of alloys are 1.5 ~ 2.0Cr, 3.2 ~ 4.0W, 3.7 ~ 4.5Co, 2.2 ~ 3.0Al, 0.7 ~ 1.0Mo, 3.2B, remain Ni (wt%). When the welding parameters are bonding temperature 1200?C, holding time 8.0 hour and welding pressure 0.3 MPa, the compacted joints obtained and the microstructure of TLP bonding seams were similar to base metal. The bonding joint is composed of weld center zone, isothermal solidification zone and diffusion-affected zone. Within joint, the elements diffusion is sufficient and borides in the diffusion zone are fewer.

Interfacial structure and mechanical property of Mg/Al alloy joint diffusion bonded with Zn interlayer metal

The characteristics of microstructure and mechanical strength of the Mg/Al alloy joint diffusion bonded with a Zn interlayer were studied by means of metalloscopy,X-ray diffraction(XRD),electron probe microanalysis(EPMA) and mechanical property test.Investigations showed that the Mg/Al alloy joint diffusion bonded with Zn interlayer consists of a multilayer sandwich structure,including the transition zone on Al side,Zn and Zn-Mg transition zone,as well as the transition zone on Mg side.The transition zone on Al side is very thin and composed mainly of a solid solution structure,while the Zn-Mg transition zone has a relative larger dimension after a rapid eutectic reaction.The addition of zinc interlayer inhibits the inter-diffusion of Mg and Al alloy efficiently.The Zn-Mg transition zone constitutes the main part of the joint and consists of Mg crystals and the new phase formed is MgZn intermetallic compound.The mechanical strength of Mg/Al alloy joints diffusion bonded with Zn interlayer reached 42 MPa.According to the phase constitution analyses executed on each side of the fracture face,it was deduced that the fracture of Mg/Al alloy joint located around the interface of Zn and Zn-Mg transition zone.

Microstructure and mechanical properties of Mg-to-Al dissimilar welded joints with an Ag interlayer using ultrasonic spot welding

Lightweight ZEK100-0 Mg alloy and A16022-T43 Al alloy with an Ag interlayer were joined via ultrasonic spot welding(USW),focusing on the microstructural change and tensile lap shear strength of the welded joints in relation to welding energy.Mg/Al interface was superseded by Mg/Ag and Al/Ag interfaces,and unfavorable Mg门A-intermetallic compound was eliminated.Ag foil was observed to be intact in the nugget center,while it was broken or dissolved at the nugget edge at high welding energy levels.The diffusion layer at the Mg/Ag interface consisted of two distinctive sub-layers:Mg3Ag intermetallic compound adjoining Ag foil,and Mg3Ag-l-Mg eutectic structure adjacent to Mg.Only a thin diffusion layer consisting mainly of Ag3Al occurred al lhe Al/Ag interface.The tensile lap shear strength first increased,reached its peak value,and then decreased with increasing welding energy.The shear strength achieved in the present study was〜31%higher than that of the joint without interlayer.Interfacial failure occurred at all energy levels,with Ag foil particles or fragments being stuck on both Mg and Al sides due to its intense interaction with Mg and Al via accelerated diffusion during USW.The results obtained pave the way for the challenging dissimilar welding between Mg and Al alloys.

High-temperature tribological properties of Ni-P alloy coatings deposited by electro-brush plating

High-temperature tribological properties of Ni-P alloy coatings processed by electro-brush plating on 20CrMo steel have been investigated. A baU-on-disc configuration was employed and 4 mm diameter Si3N4 balls were used as static counterpart. All the wear tests were carried out at 450℃ for 180 rain without lubricants. The electro-brush plating Ni-P coating is amorphous in as-deposited condition, and it becomes polycrystalline with the formation of Ni and Ni3P after heat treatment at 450℃for 1 h. The friction coefficient of the Ni-P coating is just 50% of that of the 20CrMo steel at the friction temperature of 450℃. A mild adhesive wear mechanism was found for the electro-brush plating Ni-P coating tested at 450℃, whereas for the 20CrMo steel at the same temperature a mixed adhesive and abrasive wear mechanism was observed.

Effect of interlayer cooling time on the temperature field of 5356-TIG wire arc additive manufacturing

In the paper, the finite element model(FEM) of wire arc additive manufacturing(WAAM) by TIG method was established by the ABAQUS soft, and the phase transformation latent heat was considered in the model. The evolution rules of temperature field at the interlayer with the cooling time of 10 s, 30 s and 50 s were obtained by the model. The WAAM experiment were performed by 5356 aluminum alloy welding wire with φ1.2 mm, and the simulated temperature field were varified by the thermocouple. The result shows that the highest temperature at the molten pool center increases with the increased interlayers at the same interlayer cooling time;the highest temperature drops gradually and the decline is smaller with the increased interlayer cooling time at the same layer. No remelting occurs at the top layer, and at least two remelting times occur in the other layers, resulting in complex temperature field evolution.

High-temperature Compressive Performance of Mg Alloy Foams Coated with Ni-P Layer

Mg/Ni hybrid foams were fabricated by the electroless method.The Ni-P(Nickel-Phosphorous)coatings were deposited on the surface of closed-cell Mg alloy foams.The composition,microstructure and phases of the Ni-P coatings were characterized by scanning electron microscopy(SEM),energy-dispersive X-ray spectroscopy(EDS)and X-ray diffraction(XRD),respectively.The compressive tests were performed on the Mg/Ni hybrid foams at 400℃using the Mg alloy foams as a reference.The experimental results show that the yield strength,plateau stress and energy absorption capacity of the closed-cell Mg alloy foams at high temperature were improved by the Ni-P coating.And there are four main modes for the Mg/Ni hybrid foam failure at 400℃,i e,shearing in cell wall,bending in cell edge,shedding and cracking in Ni-P coating.

Investigation on a Non-cyanide Plating Process of Ni-P Coating on Magnesium Alloy AZ91D

In this research we presented a non-cyanide plating process of Ni-P alloy coating on Mg alloy AZ91D. By applying a new process flow of electroless nickel plating in which zinc coating is used as transition of Ni-P coating on Mg alloy AZ91D, the process of copper transition coating plated in the cyanides bath can be replaced. A new bath composed of NiSO4 was established by orthogonal test. The results show that zinc transition coating can increase the adhesion and protect the Mg alloy substrate from the bath corrosion. The optimal plating bath composition is NiSO4·6H2O 20 g/L, NaH2PO2·H2O20g/L and C6H8O7·H2O 2.5 g/L, and optimal bath acidity and optimal plating temperature are pH 4.0 and 95℃, respectively. The present process flow is composed of ultrasonic cleaning→alkaline cleaning→acid pickling→activation→double immersing zinc→electroplating zinc→electroless nickel plating→passivation treatment. The present non-cyanide process of electroless nickel plating is harmless to our surroundings and Ni-P coating on Mg alloy AZ91D produced by present process possesses good adhesion and corrosion resistance.

Electrochemical behavior of Cu-Zn-Al shape memory alloy after surface modification by electroless plated Ni-P

The electrochemical behavior of Cu-Zn-Al shape memory alloy (SMA) with andwithout electroless plated Ni-P was investigated by electrochemical methods, in artificial Tyrode'ssolution. The results showed that Cu-Zn-Al SMA engendered dezincification corrosion in Tyrode'ssolution. The anodic active current densities as well as electrochemical dissolution sensitivity ofthe electroless plated Ni-P Cu-Zn-Al SMA increased with NaCl concentration rising, pH of solutiondecreasing and environmental temperature uprising. X-ray diffraction analysis indicated that aftersurface modification by electroless plated Ni-P, an amorphous plated film formed on the surface ofCu-Zn-Al SMA. This film can effectively isolate matrix metal from corrosion media and significantlyimprove the electrochemical property of Cu-Zn-Al SMA in artificial Tyrode's solution.

Improvement of microstructure and corrosion properties of friction stir welded AA5754 by adding Zn interlayer

This study investigated the effect of Zn foil layers on the microstructure and corrosion characteristics of friction stir welded aluminum alloy 5754.Samples of various joints were prepared by applying different rotational and welding speeds,and their microstructures were evaluated via a metallographic technique and scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy elemental analysis.The anticorrosion behavior of joints in the absence and presence of a Zn interlayer was studied by cyclic potentiodynamic polarization test in 3.5 wt% Na Cl aqueous solution,and sound welds were obtained in the presence of the Zn interlayer foil.The results revealed that the joint made at a rotational speed of 800 r/min and traveling speed of 15 mm/min achieved a chemical composition identical to that of aluminum alloy 7 xxx series,and as such,it showed the best resistance to corrosion.

TEMPERATURE DEPENDENCE UPON VISCOSITY OF Ni-P ALLOY ON AMORPHOUS FORMATION

The viscous flow of amorphous alloys near T_gis closely related to the viscosity of liquid alloys. On the basis of the measured surface tension and density for Ni-P binary alloys,the correla- tion between the viscosity of the melt and viscous flow process of the amorphous alloy is inves- tigated.The relationship between viscosity and temperature for Ni-P alloys going from liquid to amorphous solid may be described by the following formula:

APPLICATION OF MAXIMUM ENTROPY METHOD TO CALCULATE RDF OF Ni-P AMORPHOUS ALLOY FROM X-RAY DIFFRACTION DATA

Experiments clarified that application of the maximum entropy method to calculate the RDF (radial distribution function)of the Ni-P amorphous alloy from fewer data of its X-ray diffraction data shows a higher resolution and good consistent with known results.It is be- lieved that this method is available for the analysis of amorphous structure.

连接温度对W/Ni/Kovar真空扩散连接接头界面结构及结合强度的影响

以Ni箔为中间层材料,采用真空扩散连接方法进行W与Kovar合金的连接,研究了连接温度对W/Ni/Kovar接头界面结构和剪切强度的影响。结果表明:在520~1000℃范围内,利用真空扩散连接工艺均可成功制备出W/Ni/Kovar接头样品。随着连接温度的升高,Kovar/Ni界面与Ni/W界面的扩散层厚度逐渐增加,而接头剪切强度呈先上升后下降的趋势。当连接温度为800℃时,样品的接头剪切强度高达182 MPa,此时主要发生W块体的剪切断裂。

WE43/Zn/1060异种金属搅拌摩擦焊接头组织及性能研究

Mg/Al异种合金搅拌摩擦焊(friction stir welding,FSW)存在相容性差、接头易形成脆性金属间化合物等问题,Zn作为中间层对改善接头中脆性金属间化合物的成分及含量有重要影响。以WE43稀土镁合金和1060铝合金为研究对象,选焊接进给速度为50 mm/min、转速为1050 r/min、Zn夹层厚度为0.05 mm,进行异种合金搅拌摩擦焊试验。用X射线衍射(XRD)、扫描电子显微镜(SEM)、能谱分析(EDS)、硬度及拉伸测试等对焊接后接头的显微组织和力学性能进行研究。结果表明:添加Zn后焊缝表面无宏观变形、裂纹等缺陷;接头形成细小的Mg-Zn脆性金属间化合物Al_(5)Mg_(11)Zn_(4)、Mg-Zn,代替了无Zn接头中的Mg-Al脆性金属间化合物Al_(3)Mg_(2)、Al_(12)Mg_(17),减少了Mg-Al脆性金属间化合物的生成,从而改善接头中脆性金属间化合物(IMC)的种类与数量,添加Zn的FSW接头静载拉伸断口为脆-韧混合断裂,代替了无Zn接头的脆性断裂。因此,Zn为中间层可减少接头脆性金属间化合物的产生,提高接头的伸长率、抗拉强度等。

Migrating behaviors of interfacial elements and oxide layers during diffusion bonding of 6063Al alloys using Zn interlayer in air

The oxide layer on the surface has always been a key obstacle to achieving the diffusion bonding of Al alloys.It is a challenge for performing diffusion bonding without removing oxide layers.Herein,diffusion bonding of Al alloy retaining continuous oxide layers was successfully achieved in the air by a low-temperature and low-pressure diffusion bonding mothed using a Zn interlayer.During the bonding processes,conducted at 360℃ and 3 MPa,Zn diffused into Al through cracks of thin oxide layers to form the joint composed Al/(diffusion layer)/(oxide layer)/(Zn)/(oxide layer)/(diffusion layer)/Al.The diffusion layers were composed of Zn-Al eutectoid,and the oxide layer included nanocrystals and amorphous Al_(2)O_(3).The shear strength of joints containing continuous oxide layers was about 30 MPa.Interestingly,the migration behavior toward the joint center of the interfacial oxide layers was observed with consuming of the Zn interlayer.The cracking phenomenon,the“subcutaneous diffusion”and the migration behavior of oxide layers were verified and analyzed by the diffusion bonding of anodized 6063Al-6063Al.Subsequently,the dynamic migration mechanism of oxide layers with elements diffusion and bonding interface strengths were discussed in detail.The ability to join Al alloys in the air at low temperatures and low pressure suggests a highly practical and economic method for diffusion bonding.

Dissimilar ultrasonic spot welding of Mg-Al and Mg-high strength low alloy steel

Sound dissimilar lap joints were achieved via ultrasonic spot welding （USW）, which is a solid-state joining technique. The addition of Sn interlayer during USW effectively blocked the formation of brittle Al12Mg17 intermetallic compound in the Mg-Al dissimilar joints without interlayer, and led to the presence of a distinctive composite-like Sn and Mg2Sn eutectic structure in both Mg- Al and Mg-high strength low alloy （HSLA） steel joints. The lap shear strength of both types of dissimilar joints with a Sn interlayer was significantly higher than that of the corresponding dissimilar joints without interlayer. Failure during the tensile lap shear tests occurred mainly in the mode of cohesive failure in the Mg- Al dissimilar joints and in the mode of partial cohesive failure and partial nugget pull-out in the Mg-HSLA steel dissimilar joints.

Ni–P coating on AZ31 magnesium alloy and its crystallization

Amorphous Ni-P coating was plated on AZ31 magnesium alloy via the electroless plating technique, and the plated alloy was subsequently annealed. X-ray dif- fraction （XRD）, scanning electron microscopy （SEM）, energy dispersive spectroscopy （EDS）, and differential scanning calorimetry （DSC） were used to characterize the coating. The results show that the hardness of the coating is much higher than that of bare magnesium alloy, which further increases after crystallization. The electrochemical polarization and salt spray tests show that the coating exhibits a much higher corrosion resistance than that of the bare magnesium alloy. Moreover, the crystallized coating still exhibits a much stronger corrosion resistance than that of the bare magnesium alloy, although its corrosion resistance is lower than that of the as-plated one.

On the formation of the interlayer between Ni-P coating and AZ33magnesium alloy substrate by means of in situ SEM observation

Pre-treatment process is the key step for electroless plating. Once a suitable pre-treatment film is in place, the desired metals can be plated. In this paper, Ni-P coating was successfully prepared on AZ33 magnesium alloy with Mg（OH）2 pre-treatment film by electroless plating. To investigate the role of MgF2 in Ni-P coating, the deposition procedures between Mg（OH）2 pre-treatment film and Mg（OH）2-MgF2 pre-treatment film （a traditional process） were compared. The surface morphology variations of coatings were observed with scanning electron microscopy and the compositions were analyzed by energy dispersive spectrometry. The results showed that during the plating, both MgF2 and Ni-P deposited at the initial stage, and MgF2 distributed in the bottom of the coating, forming a transitional interlayer with Ni- P. According to the heat quench test, a poor adhesion of the coating mainly occurred between the MgF2 and Ni-P coating.

Influence of diffusion bonding conditions on bonding strength of damping copper alloy to stainless steel

The experimental investigation of different transition metals was carried out in the diffusion bonding joints of Cu alloys (CuAlBe) to stainless steel (1Cr18Ni9Ti). The microstructure of the joint was analyzed with microscopic examination, SEM, EPMA and X ray diffraction. Following conclusions have been drawn: (1) The joint strength with the Ni interlayer was higher than that with Cu interlayer when the welding parameters were same;(2)When Ni interlayer was thinner,Al could interact with Ni and Fe,and the intermetallic compounds,such as Fe 3Al etc,were formed in the interface,which decreased the strength of the joints;(3)When the bonding temperature was higher,because of the diffusion of Cu in Ni being faster than Ni in Cu,a Kirkendall effect was produced,which also decreased the strength of the joints.