6061 aluminium alloy and AZ31B magnesium alloy was successfully joined together with the addition of Zn interlayer by gas tungsten arc welding assisted hybrid ultrasonic seam welding. The effects of Zn interlayer on the microstructure and mechanical properties of the joints were investigated in detail. The results indicated that the Zn interlayer could restrain the formation of brittle Mg–Al IMCs, which were replaced by Mg–Zn IMCs. The maximum lap strength of the joints with Zn interlayer was ∼16.25 MPa, which was ∼30 increase over the joints without Zn interlayer. All the joint failures occurred by the interface mode rather than the pullout mode at the Mg/Zn interface.
KashyapK. T., MuraliS., RamanK. S. and MurthyK. S. S.: ‘Casting and heat treatment variables of AI–7Si–Mg alloy’, Mater. Sci. Technol., 1993, 9, 189–203.
2.
ParayF., KulunkB. and GruzleskiJ.: ‘Effect of strontium on microstructure and properties of aluminium based extrusion alloy6061’, Mater. Sci. Technol., 1996, 12, 315–322.
3.
WanJ., FengJ. C. and WangY. X.: ‘Microstructure of Al–Mg dissimilar weld made by cold metal transfer MIG welding’, Mater. Sci. Technol., 2008, 24, 827–831.
4.
PennerP., LiuL., GerlichA. and ZhouY.: ‘Feasibility study of resistance spot welding of dissimilar Al/Mg combinations with Ni based interlayers’, Sci. Technol. Weld. Join., 2013, 18, 541–550.
5.
LiuL. M., ZhaoL. M. and WuZ. H.: ‘Influence of holding time on microstructure and shear strength of Mg–Al alloys joint diffusion bonded with Zn–5Al interlayer’, Mater. Sci. Technol., 2011, 27, 1372–1376.
6.
ChenY. C. and NakataK.: ‘Friction stir lap joining aluminum and magnesium alloys’, Scr. Mater., 2008, 58, 433–436.
7.
QiX. D. and LiuL. M.: ‘Fusion welding of Fe-added lap joints between AZ31B magnesium alloy and 6061 aluminum alloy by hybrid laser-tungsten inert gas welding technique’, Mater. Des., 2012, 33, 436–443.
8.
SternA. and AizenshteinM.: ‘Magnetic pulse welding of Al to Mg alloys: structural–mechanical properties of the interfacial layer’, Mater. Sci. Technol., 2011, 27, 1809–1813.
9.
ZhangH. T., DaiX. Y. and FengJ. C.: ‘Interfacial microstructure and mechanical properties of Al/Mg butt joins made by MIG welding process with Zn–Cd alloy as interlayer’, J. Wuhan Univ. Technol., 2014, 29, 1258–1264.
10.
StaoY. S., ShiotaA., KokawH., OkamotoK., YangQ. and KimC.: ‘Effect of interfacial microstructure on lap shear strength of friction stir spot weld of aluminum alloy to magnesium alloy’, Sci. Technol. Weld. Join., 2010, 15, 319–324.
11.
DoumanidisC. and GaoY.: ‘Mechanical modeling of ultrasonic welding’, Weld. J., 2004, 140–146.
12.
GouldJ. E.: ‘Joining aluminum sheet in the automotive industry – a 30 year history’, Weld. J., 2012, 23–34.
13.
ZhangC. Y., ChenD. L. and LuoA. A.: ‘Joining 5754 automotive aluminum alloy 2-mm-thick sheets using ultrasonic spot welding’, Weld. J., 2014, 131–138.
14.
YangJ. W., CaoB., HeX. C. and LuoH. S.: ‘Microstructure evolution and mechanical properties of Cu–Al joints by ultrasonic welding’, Sci. Technol. Weld. Join., 2014, 19, 500–504.
15.
ShakilM., TariqN. H., AhmadM., ChoudharyM. A. and AkhterJ. I.: ‘Effect of ultrasonic welding parameters on microstructure and mechanical properties of dissimilar joints’, Mater. Des., 2014, 55, 263–273.
16.
TsujinoJ., UeokaT., KashinoT. and SugaharaF.: ‘Transverse and torsional complex vibration systems for ultrasonic seam welding of metal plates’, Ultrasonics, 2000, 38, 67–71.
17.
DoumanidisC. and GaoY.: ‘Mechanical modeling of ultrasonic welding’, Weld. J., 2004, 83, 140–146.
18.
DaiX. Y., ZhangH. T., LiuJ. H. and FengJ. C.: ‘Microstructure and properties of Mg/Al joint welded by gas tungsten arc welding-assisted hybrid ultrasonic seam welding’, Mater. Des., 2015, 77, 65–71.
19.
ZhangH. T., DaiX. Y. and FengJ. C.: ‘Joining of aluminum and magnesium via pre-roll-assisted A-TIG welding with Zn interlayer’, Mater. Lett., 2014, 122, 49–51.
20.
ZhangH. T. and SongJ. Q.: ‘Microstructural evolution of aluminum/magnesium lap joints welded using MIG process with zinc foil as an interlayer’, Mater. Lett., 2011, 65, 3292–3294.
21.
LiuF., ZhangZ. D. and LiuL. M.: ‘Microstructure evolution of Al/Mg butt joints welded by gas tungsten arc with Zn filler metal’, Mater. Charact., 2010, 69, 84–89.
22.
ZhaoL. M. and ZhangZ. D.: ‘Effect of Zn alloy interlayer on interface microstructure and strength of diffusion-bonded Mg–Al joints’, Scr. Mater., 2008, 58, 283–286.
23.
LiuL. M., LiuF. and ZhuM. L.: ‘Study on Mg/Al weld seam based on Zn–Mg–Al ternary alloy’, Materials, 2014, 7, 1173–1187.
24.
PatelV. K., BholeS. D. and ChenD. L.: ‘Microstructure and mechanical properties of dissimilar welded Mg–Al joints by ultrasonic spot welding technique’, Sci. Technol. Weld. Join., 2012, 17, 202–206.
25.
PatelV. K., BholeS. D. and ChenD. L.: ‘Improving weld strength of magnesium to aluminum dissimilar joints via tin interlayer during ultrasonic spot welding’, Sci. Technol. Weld. Join., 2012, 17, 342–347.
26.
MacwanA., PatelV. K., JiangX. Q., LiC., BholeS. D. and ChenD. L.: ‘Ultrasonic spot welding of Al/Mg/Al tri-layered clad sheets’, Mater. Des., 2014, 62, 344–351.
27.
PatelV. K., BholeS. D. and ChenD. L.: ‘Formation of zinc interlayer texture during dissimilar ultrasonic spot welding of magnesium and high strength low alloy steel’, Mater. Des., 2013, 45, 236–240.
28.
RobsonJ., PanteliA. and PrangnellP. B.: ‘Modelling intermetallic phase formation in dissimilar metal ultrasonic welding of aluminium and magnesium alloys’, Sci. Technol. Weld. Join., 2012, 17, 447–453.
