Effects of cold metal transfer mode on the reaction layer of wire and arc additive-manufactured Ti-6Al-4V/Al-6.25Cu dissimilar alloys

Components of Ti and Al dissimilar alloys were obtained by wire and arc additive manufacturing using two cold metal transfer(CMT)modes.Direct current CMT(DC-CMT)mode was used for Ti alloy deposition,and DC-CMT or CMT plus pulse(CMT+P)mode was used for the Al alloy deposition.During deposition of the first Al alloy layer,little and a significant amount of Ti alloy were melted using DC-CMT and CMT+P mode,respectively.TiAl_(3)formed in the reaction layer when DC-CMT mode was used,while TiAl_(3),TiAl,and Ti3Al formed in the reaction layer when CMT+P mode was used.Compared to using DC-CMT mode,more cracks occurred when using CMT+P.The nanohardness of the reaction layer was between that of the Al and Ti alloys,irrespective of the CMT modes.The average tensile strengths of the samples using DC-CMT and CMT+P mode were 108 MPa and 24 MPa,respectively.DC-CMT mode was more suitable for the wire and arc additive manufacturing of Ti/Al dissimilar alloys.

Fatigue Crack Growth Behavior of Different Zones in an Annealed Automatic Gas Tungsten Arc Weld Joint of TA16 and TC4 Titanium Alloys

Based on the investigated microstructure of different zones in the annealed automatic gas tungsten arc weld joint of TA16 and TC4 titanium alloys,the mechanical property of them was assessed under fatigue crack growth rate tests.For evaluation of fatigue crack growth rate,three points bending specimens were used.The correlation between the range of stress intensity factor and crack growth rate was determined in different zones of the annealed weld joint.Fatigue crack growth rates were obviously different in different zones of weld joint of dissimilar titanium alloys,due to their different microstructures.Scanning electron microscope examinations were conducted on the fracture surface in order to determine the relevant fracture mechanisms and crack growth mechanisms with respect to the details of microstructure.

Effect of Sheet Configuration on Microstructure and Mechanical Behaviors of Dissimilar Al–Mg–Si/Al–Zn–Mg Aluminum Alloys Friction Stir Welding Joints

Friction stir welding（FSW） was used to weld dissimilar Al-Mg-Si/Al-Zn-Mg aluminum alloys in this work.Influences of sheet configuration on microstructure and mechanical properties of the joints were mainly discussed.Results showed that rather different joint cross sections were obtained when using different sheet configurations.Coarser β＇ phases can be observed at the heat affected zone（HAZ） of the Al-Mg-Si alloy side,which was the main factor affecting the tensile properties and the fatigue properties.Tensile strengths of the dissimilar Al-Mg-Si/Al-Zn-Mg joints using both configurations were higher than that of the Al-Mg-Si FSW joint.When the Al-Zn-Mg alloy was located at the advancing side（AS）,the joints owned better fatigue properties due to the bridging effect of the big secondary phase particles.

Improving tensile-shear properties of friction stir lap welded dissimilar Al/Mg joints by eliminating hook defect and controlling interfacial reaction

To improve tensile-shear properties of fiction stir lap welded(FSLW) dissimilar Al/Mg joints, pin-tip profiles were innovatively designed and welding speed was optimized, and effects of them on formation, interface microstructure and mechanical properties of different FSLW joints were investigated. With increasing the welding speed, the tensile-shear load of FSLW joints produced by three pins presents an increasing firstly and then decreasing trend. Compared with Rpin, the hook and hole defect in the joints made by S-pin and T-pin are eliminated owing to additional eccentric force. Moreover, the joints obtained by T-pin at 75 mm/min have the highest tensile-shear load, and a maximum value of 3.425 kN is produced, which increases by 96.8%.Meanwhile, the pin-tip profile improves significantly the interface reaction depending on the welding temperature. For R-pin, thick brittle intermetallic compounds of about 6.9 μm Al3Mg2and 13.3 μm Al12Mg17layers at the welding interface derived from diffusion reaction are formed, resulting in continuous cracks. However, using T-pin can raise the interface temperature, and which makes the interface liquefy locally to generate only 2.2 μm Al3Mg2layer and dispersive(Al12-Mg17+Mg) eutectic structure. This can release high residual stress and remove welding crack, consequently enhancing the interface properties of T-pin joints.

Mechanical Properties of Laser Welded Joint of Copper and Steel Dissimilar Metals

In this research project,copper and stainless steel were connected by two laser welding methods:straight seam welding and swing welding.Then,electronic tensile test machine,X-ray diffractometer,scanning electron microscope and metallographic microscope were used to analyze the tensile properties,macroscopic and microscopic structure morphology and phase of the welded joint.Based on the experimental results,we determined that the strength of the straight seam welded joint was higher.Because of the intermetallic compound near the weld in the swing welding process,it leads to stress concentration,crack cracking and strength reduction.In addition,the oscillating laser beam also leads to the disorderly direction of columnar crystal and coarse structure,which makes the joint strength decrease.

Improving the mechanical property of dissimilar Al/Mg hybrid friction stir welding joint by PIO-ANN

Ultrasonic-stationary shoulder assisted friction stir welding(U-SSFSW)is a novel hybrid welding technique,which reveals promising prospect in joining Al/Mg dissimilar alloys.A thorough understanding of U-SSFSW process is imperative for the further application of this technique.Pigeon-inspired optimization(PIO)is a swarm intelligent optimization algorithm and is proposed in mathematical modeling and process optimization by artificial intelligence.In this study,PIO optimized artificial neural network(PIOANN)was firstly established to acquire the relationships between the inputs and output of the Al/Mg welding process by U-SSFSW technique.A reliable PIO-ANN was achieved and the joint with a tensile strength of 161 MPa was acquired under the PIO optimized parameters.This tensile strength is higher than any ever-reported results with the similar welding condition.The joint formation,microstructure,microhardness and fracture behaviors were systemically investigated based on the reported studies and the confirmation experiment of this study to explore the enhancing mechanism of U-SSFSW Al/Mg joint.

Microstructure and Mechanical Properties of Pulse MIG Welded 6061/A356 Aluminum Alloy Dissimilar Butt Joints

The microstructure and mechanical properties of pulse metal inert-gas （MIG） welded dissimilar joints between 4 mm thick wrought 6061-T6 and cast A356-T6 aluminum alloy plates were investigated. The tensile strength of the joints reached 235 MPa, which is 83% of that of 6061 aluminum alloy, and then decreased with the increase of travel speed while keeping other welding parameters constant. The microstructure, composition and fractography of joints were examined by the optical microscopy （OM）, scanning electron microscopy （SEM） and electron probe microanalysis （EPMA）. Grain boundary liquation and segregation occurred in the partially melted zone （PMZ） on 6061 aluminum alloy side, and brittle Fe-rich phases were observed in partially melted zone on A356 aluminum alloy side. The minimum microhardness appeared in heat-affected zone （HAZ） near A356 aluminum alloy substrate. The samples during tensile test failed mainly in PMZ and HAZ on A356 aluminum alloy side through mixed fracture mode with quasi cleavage and dimples on fracture surface.

Assessing the Bonding Interface Characteristics and Mechanical Properties of Bobbin Tool Friction Stir Welded Dissimilar Aluminum Alloy Joints

This study focuses on the bonding interface characteristics and mechanical properties of the bobbin tool friction stir welded dissimilar AA6056 and AA2219 aluminum alloy joints using diff erent welding speeds.Voids arise solely in the stir zone at the AA2219 side.A distinct boundary with limited material mixing develops at the middle section of the bonding interface,while excellent material mixing with an irregularly jagged pattern forms at the top and bottom sections of the bonding interface.Increasing the welding speed,the material mixing is rarely changed at the middle section in comparison with the bottom section.Furthermore,a small diff erence between Guinier–Preston dissolution and Q phase precipitation leads to rare change of hardness in the heat aff ected zone(HAZ)at the AA6056 side.The increased hardness of the HAZ at the AA2219 side is attributed to avoidance of the dissolution ofθ’’phase precipitates.A maximum tensile strength of 181 MPa is obtained at 300 mm min-1.Fractures occur at the AA6056 side near the top and bottom surfaces and at the bonding interface in the middle section of the joints.The regions close to the top and bottom surfaces of the joints show a better ductility.

Tensile and cyclic deformation response of friction-stir-welded dissimilar aluminum alloy joints:Strain localization effect

Cyclic deformation behavior of friction-stir-welded dissimilar AA2024-T351 to AA7075-T65 aluminum alloy joints was evaluated via stepwise tests at different strain rates,along with transmission electron microscopy examinations to characterize the precipitates required to assess internal stresses.Electron backscatter diffraction was employed to observe the inhomogeneous microstructures of the FSWed joints.Strain localization appeared in the heat affected zone(HAZ)of AA2024 side.After cyclic deformation of 500 cycles at a total strain amplitude of 0.5%,the strength of the dissimilar joints resumed basically to that of AA2024 base material.And the AA2024 HAZ was obviously hardened,which should be attributed to the introduced dislocations during cyclic deformation process.Cyclic hardening capacity of the joints increased with decreasing strain rate.

Formation of the anomalous microstructure in the weld metal of Co-based alloy/AISI 410 stainless steel dissimilar welded joint

The Co-based alloy/AISI 410 stainless steel dissimilar welded joint was fabricated by the electron beam welding(EBW)technique.The anomalous microstructure containing the element transition zone(ETZ)and/or core of tail-like zone(CTLZ)is in the weld metal(WM)adjacent to the fusion line.The melting temperature difference between the WM and AISI 410 steel,melt stirring effect and element diffusion can trigger the formation of such anomalous microstructure.In particular,the larger distance of the region in WM away from the fusion line,the smaller CTLZ and larger ETZ occurred.Compared with the fine and ellipsoidal precipitates in the as-welded CTLZ,a large number of chain-type clustered precipitates were detected in the CTLZ and ETZ interface after the aging treatment at 566°C for 1000 h.The element diffusion under elevated temperature in WM is regarded as the crucial factor for such anomalous microstructure evolution during the aging treatment.

Interface Behavior of Copper and Steel by Plasma-MIG Hybrid Arc Welding

Plasma-MIG hybrid arc welding is a hybrid heating source welding method which is composed of plasma arc and MIG arc. During Plasma-MIG hybrid arc welding process, the interface behavior of copper and steel dissimilar alloy is investigated. The results show that electromagnetic stirring effect decreases and the heat input increases with the increase of outer plasma current in the hybrid arc welding process. The interface diffusion and interface thickness is controlled by the tradeoff of electromagnetic stirring effect degradation and heat input increase. The interface diffusion and interface thickness are controlled by decreasing the electromagnetic stirring force and increasing the heat input with the increase of plasma current in Cu/Fe plasma-MIG hybrid arc welding process.