Contact reactive brazing of Al alloy/Cu/stainless steel joints and dissolution behaviors of interlayer

Contact reactive brazing of 6063 Al alloy and 1Cr18Ni9Ti stainless steel was researched by using Cu as interlayer. Effect of brazing time on microstructure of the joints, as well as the dissolution behaviors of Cu interlayer was analyzed. The results show that the product of reaction zone near 1Cr18Ni9Ti is composed of Fe2Al5, FeAl3 intermetallic compound （IMC）, and Cu-Al IMC; the near by area is composed of Al-Cu eutectic structure with Al （Cu） solid solution. With increasing the brazing time, the thickness of IMC layer at the interface increases, while the width of Al-Cu eutectic structure with Al（Cu） solution decreases. Calculation shows the dissolution rate of Cu interlayer is very fast. The complete dissolution time is about 0.47 s for Cu interlayer with 10 μm in thickness used in this study.

Structure and mechanical properties of aluminum alloy/Ag interlayer/steel non-centered electron beam welded joints

Electron beam welding was carried out between aluminum alloy and steel with Ag interlayer. Seam morphology, structure and mechanical properties of the joints were investigated with different action positions of the electron beam spot. The results show that with the increment of the beam offset to the silver side from the interface between silver and steel, the seam morphology was improved, and the porosity in the Ag interlayer vanished. A transition layer mainly composed of Ag2Al and Al eutectic was formed at the interface between silver and aluminum, and became thin and spiccato as the beam offset increased. When the beam offset was too large, two IMC layers composed of FeAl and FeAl3 respectively were formed at the interface between steel and Ag interlayer. The optimal beam offset was 0.2 mm, and the maximum tensile strength of the joint was 193 MPa, 88.9% that of the aluminum alloy, and the fracture occurred at the interface between steel and Ag interlayer.

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.

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.

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.

Diffusion bonding behaviour of β-γTiAl alloys containing high niobium with Ti interlayer by spark plasma sintering

High niobium β-γ TiAl alloy(HNBG) was diffusion bonded using spark plasma sintering with pure Ti as interlayer. The joint microstructural evolution, growth kinetics and mechanical properties were investigated. The joint included three diffusion zones. The β/B2 phase formed in the Zone Ⅰ, α_(2)phase in the Zone Ⅱ, and β-Ti and α-Ti phases in the Zone Ⅲ. The thickness of β/B2 phase, the average grain size of α_(2)phase and the amount of β-Ti phase increased with the increase of bonding temperature or bonding time. The growth activation energies of β/B2 and α_(2)phases were 582 and 253 kJ/mol, respectively. The joint acquired at 1000 °C, 10 min and 10 MPa showed the maximum shear strength of 308 MPa. Fracture mainly occurred along the interfaces between Zone Ⅰ and HNBG alloy, and between Zone I and Zone Ⅱ. Fracture mechanism of the joint was characterized by brittleness rupture along the phase boundary.

Electroless Ni-P plating on Mg-Li alloy by two-step method

Pretreated Mg-Li alloy sheets were pre-plated in a NiCO3？2Ni（OH）2？4H2O solution to form a thin Ni-P alloy film and then plating in a NiSO4？6H2O solution was carried out to obtain a protective coating.The surface morphology,structure and corrosion resistance of the coating were studied.The results showed that a flat,bright and compact plating layer,which was integrated into the matrix metal,was obtained.The P content of the Ni-P coating reached 13.56%（mass fraction）.The hardness value of the Ni-P coating was about HV 549.The polarization curve showed that the corrosion potential of the Ni-P coating reached ？0.249 V（vs SCE）.A long passivation region was found on the polarization curve,and this phenomenon indicated that the coating has an excellent anti-corrosion property.

An in situ measure method to study deposition mechanism of electroless Ni-P plating on AZ31 magnesium alloy

An in situ method was designed to measure a continuous open circuit potential （OCP） curve of AZ31 magnesium alloy and to observe the morphology variation of Ni-P coating during the process of the electroless plating. The deposition mechanism of the electroless Ni-P plating on AZ31 Mg alloy was studied by OCP curve, scanning electron microscopy （SEM）, and energy dispersion spectroscopy （EDS）. The process of electroless Ni-P plating contains the coating formation stage and the coating growth stage. The formation stage includes three procedures, i.e., the nucleation and growth of Ni crystallites, the extension of the coating in two-dimensional （2D） direction and the coalescence of the coating along three-dimensional （3D） direction. SEM investigations demonstrate that the spherical nodules of the Ni-P coating are not only formed during the coating growth stage, but also generated in the initial deposition stage of electroless Ni-P plating. The variation of the coating rates at different deposition stages corresponds to the deposition mechanism of their respective deposition stage.

Effect of novel ternary ligand system on acidic electroless Ni-P plating on AZ91D magnesium alloy

The electroless Ni-P coatings on AZ91 D magnesium alloy substrate were prepared using the acidic hypophosphite-reduced electroless nickel bath containing the novel ternary ligand system. The results indicate that the deposition rate varies with the ternary ligand concentration in plating solution. The structural and morphological characteristics of the coatings were analyzed by XRD and SEM. The anticorrosion properties of the Ni-P coatings were evaluated in 3.5% NaCl solution by electrochemical impedance and potentiodynamic polarization methods. The amount of ternary ligands in electroless plating bath has an significant effect on the surface morphology and structure of Ni-P coatings. The decrease of crystallization temperature and increase of crystallization heat of all the deposits with an increase in ternary ligand concentration are found by DSC measurements. The coating obtained with 0.035 mol/L ternary ligand additive in plating bath can offer a better surface homogeneity and improve corrosion resistance.

Electroless plating and growth kinetics of Ni-P alloy film on SiC_p/Al composite with high SiC volume fraction

After Sn/Pd activating, the SiCp/Al composite with 65% SiC (volume fraction) was coated by electroless Ni?P alloy plating. Surface morphology of the composite and its effect on the Ni?P alloy depositing process and bonding action of Ni and P atoms in the Ni?P alloy were studied. The results show that inhomogeneous distribution of the Sn/Pd activating points results in preferential deposition of the Ni?P alloy particles on the Al alloy and rough SiC particle surfaces and in the etched caves. The Ni?P alloy film has an amorphous structure where chemical bonding between Ni and P atoms exists. After a continuous Ni?P alloy film formed, electroless Ni?P alloy plating is not affected by surface morphology and characteristics of the SiCp/Al composite any longer, but by the electroless plating process itself. The Ni?P alloy film follows linear growth kinetics with an activation energy of 68.44 kJ/mol.

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.

Pretreatment-free Ni-P plating on magnesium alloy at low temperatures

Electrochemically promoted electroless plating(EPEP)was used for the application of pretreatment-free Ni-P coating on AM60B magnesium alloy at low temperatures and the obtained coating was characterized by SEM,AFM,EDS and XRD techniques.Compact,uniform,and medium-phosphorus Ni-P coating with mixed crystalline-amorphous microstructure was obtained by applying a cathodic current density of4mA/cm^2at50℃.Also,island-like nickel clusters were deposited on the alloy surface under the same plating condition but without applying the cathodic current.In addition,the durability of the magnesium alloy against corrosion was strongly improved after plating via EPEP technique which was revealed by electrochemical examinations in3.5%NaCl(mass fraction)corrosive electrolyte.The results of the electrochemical examinations were confirmed by microscopic observations.Thickness,microhardness,porosity and adhesive strength of the deposits were also qualified.

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: