SpringerLink
Log in

Investigation of modified friction stir clinching-brazing process of AA2024 Al/AZ31 Mg: metallurgical and mechanical properties

  • Original Article
  • Published:
Archives of Civil and Mechanical Engineering Aims and scope Submit manuscript

Abstract

The weldability of the AA2024-T3 and AZ31 Mg alloys was investigated using the modified friction stir clinching-brazing (MFSC-B) and probe-less friction stir spot brazing (PFSSB) processes. A 50 µm thick Zn foil-interlayer was sandwiched between the dissimilar base materials for the welding processes. The mechanical, microstructure, and weld-fracture behaviors of all joints were studied and compared. Zn-rich interdiffusion-aided lamellar and blocky structures are found at the brazed region/zone of the AA2024-T3/Zn/AZ31 joint irrespective of the welding process due to the sole influence of heat input at the zone. The differential flow in the MFSC-B joint enforces significant inter-material mingling, better distribution of Zn, and more subgrains/dislocation density at the joint as compared to the PFSSB joint. The interlayer inhibited the creation of the β-Al3Mg2 phase while the γ-Al12Mg17 phase could not be prevented in the AA2024-T3/Zn/AZ31 joints due to tool-induced atomic collision and diffusion–reaction mechanisms. Improved tensile/shear failure load is found in the MFSC-B joint (4369 N) as related to their PFSSB counterpart (3018 N) due to improved material flow (intermixing), and intense dislocation density. The MFSC-B process is thus recommended for dissimilar joining of Mg and Al alloys.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price includes VAT (Germany)

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Boucherit A, Avettand-Fènoël M-N, Taillard R. Effect of a Zn interlayer on dissimilar FSSW of Al and Cu. Mater Des. 2017;124:87–99.

    Article  Google Scholar 

  2. Paidar M, Mehrez S, Babaei B, Memon S, Ojo OO, Lankarani HM. Dissimilar welding of AA5083 to AZ31 Mg alloys using Modified friction stir clinching brazing. Mater Lett 2021;129764. https://doi.org/10.1016/j.matlet.2021.129764

  3. Paidar M, Mohanavel V, Ojo OO, Mehrez S, Rajkumar S, Ravichandran M. Dieless friction stir extrusion-brazing (DFSE-B) of AA2024-T3 aluminum alloy to copper with Zn interlayer. Results Phys. 2021;24:104101.

    Article  Google Scholar 

  4. Kumar Sahu P, Pal S, Das B, Shi Q. Fabrication and effect of Mg–Zn solid solution via Zn foil interlayer alloying in FSW process of magnesium alloy. Arch Civil Mech Eng. 2020;20:137.

    Article  Google Scholar 

  5. Hosseini VA, Aashuri H, Kokabi AH. Characterization of newly developed semisolid stir welding method for AZ91 magnesium alloy by using Mg–25%Zn interlayer. Mater Sci Eng A. 2013;565:165–71.

    Article  Google Scholar 

  6. Afghahi SS, Jafarian M, Paidar M, Jafarian M. Diffusion bonding of Al 7075 and Mg AZ31 alloys: process parameters, microstructural analysis and mechanical properties. Trans Nonferrous Metals Soc China. 2016;26:1843–51.

    Article  Google Scholar 

  7. Malarvizhi S, Balasubramanian V. Influences of tool shoulder diameter to plate thickness ratio (D/T) on stir zone formation and tensile properties of friction stir welded dissimilar joints of AA6061 aluminum–AZ31B magnesium alloys. Mater Des. 2012;40:453–60.

    Article  Google Scholar 

  8. Wang Y, Prangnell PB. The significance of intermetallic compounds formed during interdiffusion in aluminum and magnesium dissimilar welds. Mater Charact. 2017;134:84–5.

    Article  Google Scholar 

  9. Choi D-H, Ahn B-W, Lee C-Y, Yeon Y-M, Song K, Jung S-B. Formation of intermetallic compounds in Al and Mg alloy interface during friction stir spot welding. Intermetallics. 2011;19:125–30.

    Article  Google Scholar 

  10. Singh VP, Patel SK, Ranjan A, Kuriachen B. Recent research progress in solid-state friction-stir welding of aluminum-magnesium alloys: a critical review. J Mater Res Technol. 2020;9:6217–56.

    Article  Google Scholar 

  11. Peng P, Wang K, Wang W, Yang T, Liu Q, Zhang T, Zhang S, Cai J, Qiao K, Wang L, Wang H, Liu J. Intermetallic compounds: formation mechanism and effects on the mechanical properties of friction stir lap welded dissimilar joints of magnesium and aluminum alloys. Mater Sci Eng A. 2021;802:140554.

    Article  Google Scholar 

  12. Liang Z, Qin G, Wang L, Meng X, Li F. Microstructural characterization and mechanical properties of dissimilar friction welding of 1060 aluminum to AZ31B magnesium alloy. Mater Sci Eng A. 2015;645:170–80.

    Article  Google Scholar 

  13. Mehta KP, Carlone P, Astarita A, Scherillo F, Rubino F, Vora P. Conventional and cooling assisted friction stir welding of AA6061 and AZ31B alloys. Mater Sci Eng A. 2019;759:252–61.

    Article  Google Scholar 

  14. Mofid MA, Abdollah-Zadeh A, Malek Ghaini F. The effect of water cooling during dissimilar friction stir welding of Al alloy to Mg alloy. Mater Des. 2012;36:161–7. https://doi.org/10.1016/j.matdes.2011.11.004.

    Article  Google Scholar 

  15. Zhao J, Chuan Song W, Hao S. Ultrasonic effect on thickness variations of intermetallic compound layers in friction stir welding of aluminum/magnesium alloys. J Manuf Process. 2021;62:388–402.

    Article  Google Scholar 

  16. Peng H, Chen DL, Bai XF, She XW, Li DY, Jiang XQ. Ultrasonic spot welding of magnesium-to-aluminum alloys with a copper interlayer: microstructural evolution and tensile properties. J Manuf Process. 2019;37:91–100.

    Article  Google Scholar 

  17. Raval SK, Judal KB. Recent advances in dissimilar friction stir welding of aluminum to magnesium alloys. Mater Today Proc. 2020;22:2665–75.

    Article  Google Scholar 

  18. Zhou X, Chen Y, Li S, Huang Y, Hao K, Peng P. Friction stir spot welding-brazing of Al and hot-dip aluminized Ti alloy with Zn interlayer. Metals. 2018;8(922):1–13.

    Google Scholar 

  19. Paidar M, Ashraff Ali KS, Mohanavel V, Mehrez S, Ravichandran M, Ojo OO. Weldability and mechanical properties of AA5083-H112 aluminum alloy and pure copper dissimilar friction spot extrusion welding-brazing. Vacuum. 2021;187:110080.

    Article  Google Scholar 

  20. Gao Y, Morisada Y, Fujii H, Liao J. Dissimilar friction stir lap welding of magnesium to aluminum using plasma electrolytic oxidation interlayer. Mater Sci Eng A. 2018;711:109–18.

    Article  Google Scholar 

  21. Abdollahzadeh A, Shokuhfar A, Cabrera JM, Zhilyaev AP, Omidvar H. The effect of changing chemical composition on dissimilar Mg/Al friction stir welded butt joints using zinc interlayer. J Manuf Process. 2018;34:18–30.

    Article  Google Scholar 

  22. Deng H, Chen Y, Zhang T, Wang S, Yin L, **e J. Effect of Zn-brazed-interface on microstructures and mechanical properties of dissimilar 2A12/AZ31 alloys friction stir lap welds. Mater Lett. 2019;255:126543.

    Article  Google Scholar 

  23. Peng H, Chen DL, Bai XF, Wang PQ, Li DY, Jiang XQ. Microstructure and mechanical properties of Mg-to-Al dissimilar welded joints with an Ag interlayer using ultrasonic spot welding. J Magnes Alloys. 2020;8:552–63.

    Article  Google Scholar 

  24. Li J, Tang F, Paiadr M. Modified friction stir clinching-brazing of brass to AA5083 aluminum alloy using Zn interlayer. Arch Civil Mech Eng. 2021;21:13.

    Article  Google Scholar 

  25. Paidar M, Mehrez S, Ojo OO, Mohanavel V, Babaei B, Ravichandran M. Modified friction stir clinching of AA6061-T6/AA5754-O joint: effect of tool rotational speed and solution heat treatment on mechanical, microstructure, and fracture behaviors. Mater Charact. 2021;173:110962.

    Article  Google Scholar 

  26. Memon S, Paidar M, Mehrez S, Cooke K, Ojo OO, Lankarani H. Effects of materials positioning and tool rotational speed on metallurgical and mechanical properties of dissimilar modified friction stir clinching of AA5754-O and AA2024-T3 sheets. Results Phys. 2021;22:103962.

    Article  Google Scholar 

  27. Paidar M, Vaira Vignesh R, Moharrami A, Ojo OO, Jafari A, Sadreddini S. Development and characterization of dissimilar joint between AA2024-T3 and AA6061-T6 by modified friction stir clinching process. Vacuum. 2020;176:109298.

    Article  Google Scholar 

  28. Memon S, Paidar M, Ojo OO, Cooke K, Babaei B, Masoumnezhad M. The role of stirring time on the metallurgical and mechanical properties during modified friction stir clinching of AA6061-T6 and AA7075-T6 sheets. Results Phys. 2020;19:103364.

    Article  Google Scholar 

  29. Paidar M, Tahani K, Vaira Vignesh R, Ojo OO, Ezatpour HR, Moharrami A. Modified friction stir clinching of 2024–T3 to 6061–T6 aluminium alloy: effect of dwell time and precipitation-hardening heat treatment. Mater Sci Eng A. 2020;791:139734.

    Article  Google Scholar 

  30. Paidar M, Memon S, Olegovich Samusenkov V, Babaei B, Ojo OO. Friction spot extrusion welding-brazing of copper to aluminum alloy. Mater Lett. 2021;285:129160.

    Article  Google Scholar 

  31. Lin Y-J, Lin C-S. Galvanic corrosion behavior of friction stir welded AZ31B magnesium alloy and 6N01 aluminum alloy dissimilar joints. Corros Sci. 2021;180:109203.

    Article  Google Scholar 

  32. Sato YS, Park SHC, Michiuchi M, Kokawa H. Constitutional liquation during dissimilar friction stir welding of Al and Mg alloys. Scripta Mater. 2004;50:1233–6.

    Article  Google Scholar 

  33. Dong Z, Song Qi, Ai X, Lv Z. Effect of joining time on intermetallic compound thickness and mechanical properties of refill friction stir spot welded dissimilar Al/Mg alloys. J Manuf Process. 2019;42:106–12.

    Article  Google Scholar 

  34. Firouzdor V, Kou S. Formation of liquid and intermetallics in Al-to-Mg friction stir welding. Metall Mater Trans A. 2010;41:3238–51.

    Article  Google Scholar 

  35. Oladimeji OO, Taban E, Kaluc E. Understanding the role of welding parameters and tool profile on the morphology and properties of expelled flash of spot welds. Mater Design. 2016;108:518–28.

    Article  Google Scholar 

  36. Paidar M, Vaira Vignesh R, Khorram A, Oladimeji Ojo O, Rasoulpouraghdam A, Pustokhina I. Dissimilar modified friction stir clinching of AA2024-AA6061 aluminum alloys: effects of materials positioning. J Mater Res Technol. 2020;9:6037–47.

    Article  Google Scholar 

  37. Ashraff Ali KS, Mehrez S, Ojo OO, Mohanavel V, Yoganandam K, Ravichandran M. Modified friction stir clinching of AA5754-O to AA6061-T6: the role of shoulder feature on the metallurgical and mechanical properties. Vacuum. 2021;187:110109.

    Article  Google Scholar 

  38. Asl NS, Mirsalehi SE, Dehghani K. Effect of TiO2 nanoparticles addition on microstructure and mechanical properties of dissimilar friction stir welded AA6063-T4 aluminum alloy and AZ31B-O magnesium alloy. J Manuf Process. 2019;38:338–54.

    Article  Google Scholar 

  39. Mohammadi J, Behnamian Y, Mostafaei A, Izadi H, Saeid T, Kokabi AH, Gerlich AP. Friction stir welding joint of dissimilar materials between AZ31B magnesium and 6061 aluminum alloys: microstructure studies and mechanical characterizations. Mater Charact. 2015;10:189–207.

    Article  Google Scholar 

  40. Rao HM, Jordon JB, Ghaffari B, Su X, Khosrovaneh AK, Barkey ME, Yuan W, Guo M. Fatigue and fracture of friction stir linear welded dissimilar aluminum-to-magnesium alloys. Int J Fatigue. 2016;82:737–47.

    Article  Google Scholar 

  41. Chen Y, Nakata K. Friction stir lap joining aluminum and magnesium alloys. Scr Mater. 2008;58:433–6.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Materials Engineering, South Tehran Branch, Islamic Azad University, 1459853849, Tehran, Iran

    Moslem Paidar

  2. School of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran

    Amirreza Kazemi

  3. Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj, 16273, Saudi Arabia

    Sadok Mehrez

  4. Department of Mechanical Engineering, University of Tunis El Manar, ENIT, BP 37, Le Belvédère, 1002, Tunis, Tunisia

    Sadok Mehrez

  5. Department of Industrial and Production Engineering, The Federal University of Technology, Akure, Nigeria

    Olatunji Oladimeji Ojo

  6. Data Science and Computational Intelligence Research Group, Information Technology Department, Universitas Sumatera Utara, Medan, Indonesia

    Mahyuddin Khairuddin Matyuso Nasution

  7. Sechenov First Moscow State Medical University, Moscow, Russia

    Sergei Nikolaevich Mironov

Authors
  1. Moslem Paidar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Amirreza Kazemi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Sadok Mehrez
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Olatunji Oladimeji Ojo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Mahyuddin Khairuddin Matyuso Nasution
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Sergei Nikolaevich Mironov
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Moslem Paidar or Mahyuddin Khairuddin Matyuso Nasution.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Ethical approval

We confirm that this work is original and has not been published elsewhere, nor it is currently under consideration for publication elsewhere. All authors have approved the manuscript and have agreed with its submission to your journal.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Paidar, M., Kazemi, A., Mehrez, S. et al. Investigation of modified friction stir clinching-brazing process of AA2024 Al/AZ31 Mg: metallurgical and mechanical properties. Archiv.Civ.Mech.Eng 21, 115 (2021). https://doi.org/10.1007/s43452-021-00267-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s43452-021-00267-7

Keywords

Search

Navigation