Microstructure characteristics of dissimilar metal weld between aluminum alloy and brass

Dissimilar metal joining between 5A02 aluminum alloy and H62 brass sheets was conducted by gas tungsten arc welding with Zn-15% Al and Al-12% Si flux-cored filler wires. The microstructure in the weld and distribution of major alloying elements in the intelfacial layer were examined, and the tensile strength of the resultant joints was measured. Pores appeared in the weld made with Zn-15% Al flax-cored filler wire, the interracial layer mainly consisted of AlCu phase, and the specimens fractured through the weld with tensile strength of 129 MPa. When Al-12% Si flux-cored filler wire was used, Cu diffused into the weld and Al2 Cu phase formed, and the specimens fractured along the interfacial layer with tensile strength of 122 MPa.

Corrosion behavior of aluminum/steel dissimilar metals friction stir welding joint

The corrosion performance of aluminum/steel contact and aluminum/steel FSW joint in 3.5 wt.%NaCl solution were analyzed using potentiostatic tests.The post-corrosion microstructure of the welding joint was characterized by optical microscope(OM),scanning electron microscopy(SEM)and energy dispersive spectroscopy(EDS).The results showed that the localized corrosion of FSW joint of Al/steel dissimilar metals mainly initiated at the interface transition zone(ITZ).Precipitation of intermetallic compounds(IMCs)and Fe-rich phase particles in ITZ accelerated the corrosion of the FSW joint.This phenomenon has been attributed to distinct corrosion potentials between IMCs and steel,aluminum base metal.The corrosion resistance sequence of IMCs in ITZ is Fe_(3)Al>FeAl>Fe_(2)Al_(5).

Joining of AZ31 and AZ91 Mg alloys by friction stir welding

Two dissimilar magnesium(Mg)alloy sheets,one with low aluminium(AZ31)and another with high aluminium(AZ91)content,were successfully joined by friction stir welding(FSW).The effect of process parameters on the formation of hot cracks was investigated.A sound metallurgical joint was obtained at optimized process parameters(1400 rpm with 25 mm/min feed)which contained fine grains and distributed β(Mg_(17)Al_(12))phase within the nugget zone.An increasing trend in the hardness measurements has also confirmed more amount of dissolution of aluminium within the nugget zone.A sharp interface between nugget zone and thermo mechanical affected zone(TMAZ)was clearly noticed at the AZ31 Mg alloy side(advancing)but not on the AZ91 Mg alloy side(retreating).From the results it can be concluded that FSW can be effectively used to join dissimilar metals,particularly difficult to process metals such as Mg alloys,and hot cracking can be completely eliminated by choosing appropriate process parameters to achieve sound joint.

The effect of zinc coating during joining aluminium to zinc-coated steel by welding-brazing process

An optical sensing system was constructed to study the coating when joining ahtminium alloy to zinc-coated steel by MIG welding-brazing process. The results showed that the coating fused to form a liquid zinc film on surface during process. The Al-Si filler metal reacted with the liquid zinc film to improve the spreadability of filler metal and thus a new method was established to join aluminium alloy and uncoated steel by depositing a mixed layer on steel surface.

Joining dissimilar metal of Ti and CoCrMo using directed energy deposition

We report laser cladding of pure titanium on a CoCrMo alloy using directed energy deposition.Using electron microscopy,the microstructural evolution upon varying the process parameters,especially laser power and powder feed rate,was investigated in relation to crack formation.Cladding layers showing dilution rates of more than 5%contained cracks due to the formation of the brittle Co_(2)Ti intermetallic phase.The observed cracks could be ascribed to a mismatch in thermal expansion and a resulting stress of more than 440 MPa acting on the Co_(2)Ti phase,as determined by density functional theory and nanoindentation.Furthermore,an excess laser energy caused chemical inhomogeneity and unmelted Ti powder particles,while a deficient laser energy resulted in a lack of fusion.Neither cracks nor partially melted powders were observed for a powder feed rate of 3 g/min and a laser power of 225–300 W,for which the dilution rate was minimized to less than 5%.For such samples,the cladding layers comprised pureα-Ti and a uniform CoT i interface with Co_(2)Ti islands.

Direct joining of oxygen-free copper and carbon-fiber-reinforced plastic by friction lap joining

Oxygen-flee copper （Cu） was successfully joined to carbon-fiber-reinforced thermoplastic （CFRTP, polyamide 6 with 20wt% carbon fiber addition） by friction lap joining （FLJ） at joining speeds of 200-1600 mm/min with a constant rotation rate of 1500 rpm and a nominal plunge depth of 0.9 ram. It is the first time to report the joining of CFRTP to Cu by FLJ. As the joining speed increased, the tensile shear force （TSF） of joints increased first, and decreased thereafter. The maximum TSF could reach 2.3 kN （ 15 mm in width）. Hydrogen bonding formed between the amide group of CFRTP and the thin Cu20 layer on the Cu surface, which mainly contributed to the joint bonding. The influence factors of the TSF of the joints at different joining speeds were discussed. The TSF was mainly affected by the joining area, the degradation of the plastic matrix and the number and the size of bubbles. As the joining speed increased, the influence factors varied as follows： the joining area increased first and then decreased; the degra- dation of the plastic matrix and the number and the size of bubbles decreased. The maximum TSF was the comprehensive result of the relatively large joining area, small degradation of the plastic matrix and small number and sizes of bubbles.

CuTiNiZrV Amorphous Alloy Foils for Vacuum Brazing of TiAl Alloy to 40Cr Steel

Vacuum brazing of TiAl alloy to 40Cr steel sheets was conducted with newly developed CuTiNiZrV amorphous foils. It was found that a diffusion layer,filler metal and reaction layer existed in the brazed seam. The diffusion layer in the joint brazed with Cu43.75Ti37.5Ni6.25Zr6.25V6.25(at.%) foil was flat and thin,containing Ti19Al6 and Ti2Cu intermetallic compounds; however,the diffusion layer brazed with Cu37.5Ti25Ni12.5Zr12.5V12.5 foil was uneven with bulges,consisting of essentially Ti-based solute solution. The foil with 12.5 at.% V showed inferior spreadability compared to that with 6.25 at.% V at brazing temperature. However,fracture happened along the diffusion layer with 6.25 at.% V foil due to the formation of brittle intermetallic phases,but the joints brazed with 12.5 at.% V foil failed through the TiAl substrate. These results show that designing amorphous alloy with less Ti and more V for brazing TiAl alloy to steel is appropriate.