Successful joining of dissimilar metals such as Al and Mg can provide significant advantages to the automotive industry in the fabrication of vehicle bodies and other important components. This study explores dissimilar joining of Al–Mg using a resistance spot welding process to produce microstructurally sound lap joints and evaluates the impact of interlayer composition on microstructural evolution and the formation of intermetallic compounds within the weld nugget. The results indicated that mechanically sound joints can be produced, with fine equiaxed and columnar dendrites within the weld nugget. The presence of intermetallic compounds was also confirmed by the variation in the microhardness values recorded across the weld zone.
KulekciMK.Magnesium and its alloys applications in automotive industry. Int J Adv Manuf Technol. 2008; 39(9–10):851–865. doi: 10.1007/s00170-007-1279-2
2.
LiuL, RenD, LiuF.A review of dissimilar welding techniques for magnesium alloys to aluminum alloys. Materials (Basel). 2014; 7:3735–3757. doi: 10.3390/ma7053735
3.
ManladanSM, YusofF, RameshS, A review on resistance spot welding of aluminum alloys. Int J Adv Manuf Technol. 2017; 90:605–634. doi: 10.1007/s00170-016-9225-9
4.
AmbroziakA, KorzeniowskiM.Using resistance spot welding for joining aluminium elements in automotive industry. Arch Civ Mech Eng. 2010; 10(1):5–13. doi: 10.1016/S1644-9665(12)60126-5
5.
ChoiDH, AhnB, LeeC.Formation of intermetallic compounds in Al and Mg alloy interface during friction stir spot welding. Intermetallics. 2011; 19:125–130. doi: 10.1016/j.intermet.2010.08.030
6.
PanteliA, ChenY, StrongD.Optimization of aluminum to magnesium ultrasonic spot welding. J Mater Sci. 2012; 64:414–420.
7.
ZhaoLM, ZhangZD.Effect of Zn interlayer on interface microstructure and strength of diffusion-bonded Mg-Al joints. Scr Mater. 2008; 58:283–286. doi: 10.1016/j.scriptamat.2007.10.006
8.
PennerP, LiuL, GerlichA, Dissimilar resistance spot welding of aluminum to magnesium with Zn coated steel interlayers. Weld J. 2014; 93:225–231.
9.
KimYG, KimIJ, KimJS, Evaluation of surface crack in resistance spot welds of Zn-coated steel. Mater Trans. 2014; 55(1):171–175. doi: 10.2320/matertrans.M2013244
10.
WangY, MoZ, FengJ, Effect of welding time on microstructure and tensile shear load in resistance spot welded joints of AZ31 Mg alloy. Sci Technol Weld Join. 2007; 12(8):671–676. doi: 10.1179/174329307X238380
11.
Mezbahul-IslamM, MostafaAO, MedrajM.Essential magnesium alloys binary phase diagrams and their thermochemical data. J Mater. 2014; 2014:1–33. doi: 10.1155/2014/704283
12.
ChangWS, RajeshSR, ChunCK, Microstructure and mechanical properties of hybrid laser-friction stir welding between AA6061-T6 Al alloy and AZ31 Mg alloy. J Mater Sci Technol. 2011; 27(3):199–204. doi: 10.1016/S1005-0302(11)60049-2
13.
Chrifi-AlaouiFZ, NassikM, MahdoukK, Enthalpies of formation of the Al–Ni intermetallic compounds. J Alloys Compd. 2004; 364(1–2):121–126. doi: 10.1016/S0925-8388(03)00493-6
14.
ZhongY, YangM, LiuZK.Contribution of first-principles energetics to Al–Mg thermodynamic modeling. Calphad. 2005; 29(4):303–311. doi: 10.1016/j.calphad.2005.08.004
15.
KarimiM, SedighiM, AfshariD.Thermal contact conductance effect in modeling of resistance spot welding process of aluminum alloy 6061-T6. Int J Adv Manuf Technol. 2015; 77(5–8):885–895. doi: 10.1007/s00170-014-6492-1
16.
FengY, LuoZ, LiY, A novel method for resistance plug welding of 7075 aluminum alloy. Mater Manuf Process. 2016; 31(16):2077–2083. doi: 10.1080/10426914.2015.1103853
17.
PereiraA, FerreiraJ, LoureiroA, Effect of process parameters on the strength of resistance spot welds in 6082-T6 aluminium alloy. Mater Des. 2010; 31(5):2454–2463. doi: 10.1016/j.matdes.2009.11.052
18.
RadakovicD, TumuluruMP.Redicting resistance spot weld failure modes in shear tension tests of advanced high-strength automotive steels. Weld J. 2008; 87(4):96.
