Effect of Traverse Speed on the Defect Characteristic, Microstructure, and Mechanical Property of Friction Stir Welded T-Joints of Dissimilar Mg/Al Alloy

The AZ31 B/2024-T4 T-lap-joint was successfully fabricated by friction stir welding (FSW) with different welding parameters. The defect characteristics and metallurgical structure were observed and analyzed using optical microscope (OM) and scanning electron microscopy (SEM). Besides, the effects of defects and welding parameters on mechanical properties were investigated. The results show that an effective metallurgical reaction zone can be formed between Mg and Al (Mg-Al MRZ) and the island structures and lamellar structures appeared in the Mg-Al MRZ. The T-joints without tunnel defects can be obtained and the excellent mechanical properties of the T-joint were achieved using the welding speed of 50 mm/min. The tensile strength along the skin and the stringer was mainly affected by the kiss bonding defects.

Microstructural Aspects of the Zircaloy-4/SS-304L Interface Obtained by Diffusion Bonding Technique

A dissimilar metal joining method based on diffusion bonding was developed to join 304L stainless steel (SS) and Zr alloy (Zy-4). This was done at 820°C and 950°C under argon and dynamic pressure for 45 minutes.The metallurgical structure of the interface and the evolution of its texture during the treatment were studied by evaluating the distribution of the constituent chemical elements and by identifying the crystalline phases formed. Chemical exchanges through the interface are favored by diffusion phenomena. The junction was characterized by: microscopic observations and chemical analyzes (ESEM-EDS, EPMA), X-RD and mechanical tests (HV and Shear test). Treatment at 820°C does not form a bond because the reciprocal solubilities of the chemical elements of SS and Zy-4 are very low. The junction obtained at 950°C has a reaction zone (RZ) formed at the SS/Zy-4 interface, composed of three layers. The first layer (LI = α-(Fe,Cr) on the SS side and the third layer (LIII=Zr2(Fe, Ni)) on the Zy-4 side are single-phased. The middle layer LII is biphasic (LII= e-Zr(Cr,Fe)2+Zr2(Fe, Ni)). The maximum hardness measured in the RZ is ~ 1120 HV. It is due to the formation of the intermetallic compounds of type e-Zr(Cr,Fe)2 in LII. Examination of fracture facies obtained from the joints reveals that the fracture is localized in the LIII layer and it is fragile in nature of the trans-granular type.

Metallurgical Structure of A356 Alloy Solidified by Mechanical Stirring

The study investigated the effects of mechanical stirring before solidification on the metallurgical structure of hypoeutectic aluminum-silicon A356. A series of stirring trials were conducted in the present study. Emphasis were placed on the morphological changes of the primary phase, which was subjected to different levels of stirring at various values of the rod material and its diameter, insertion temperature and rotation speed. It was found that when the rod was made of the same material as the molten metal, it acted as a nucleation site to generate numerous nucleated primary crystals, which separated from the rod surface continuously into the molten metal with the rotation of the stirring rod, resulting in the refinement and spheroidization of the primary crystals. The ideal semisolid slurry with homogeneous spherical and fine primary crystals could be obtained by optimizing rod insertion temperature, rotation speed and its diameter, which is a key factor in semi-solid forming.

Designing for Aluminum

In the design of aluminum forgings, the designer must specify the material and process and geometric details so that the component will meet performance requirements. Forging produces parts of high integrity because the process sequences refines and homogenizes metallurgical structure, elimination of material defects assuring maximum material strength. This article specifically addresses the following forging design considerations: material aspects, geometrical aspects, cost aspects, forging methods, process mechanics, and forged part design.

Effect of Zn, Mg, Cu, Zr on Microstructure and Properties of Laser Welding Aluminium Alloy

A series of Al-6.3Zn-2.3Mg-2.3Cu-0.15Zr alloys with different reduce of Zn, Mg, Cu and Zr were prepared by ingot-metallurgy processing. The metallurgical structure and mechanical properties were investigated by optical microscope, scanning electron microscopy and other equipment. The results indicated that the ingot’s microstructures of the four alloys contain the phrases of η (MgZn2) and θ (Al2Cu), which mostly distribute at the grain boundaries in a shape of continuous network. After extrusion processing, the grain of laser welding aluminium alloy was elongated along the extrusion direction, therefore forming fibrous structures, and meanwhile the second phase particles with different degrees of fragmentation were arranged along the extrusion direction since the microstructure of extruded bars was inherited by the as-cast structure. Zr could significantly inhibit recrystallization of alloy; the recrystallization of the alloy with lower Zr was more obvious. As the content of Zr reduced, the tensile strength of alloy decreased, but the electrical conductivity and hardness increased. When the content of Cu was lower, the hardness were decreased.