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Microstructure and Mechanical Properties of Ultrasonic Spot Welded Mg/Al Alloy Dissimilar Joints

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College of Engineering and Technology, Southwest University, Tiansheng Road 2, Beibei District, Chongqing 400715, China
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Department of Mechanical and Industrial Engineering, Ryerson University, 350 Victoria Street, Toronto, ON M5B 2K3, Canada
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Faculty of Materials and Energy, Southwest University, Tiansheng Road 2, Beibei District, Chongqing 400715, China
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Advanced Materials Research Center, Chongqing Academy of Science and Technology, Yangliu Road 2, Chongqing 401123, China
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Department of Chemical and Materials Engineering, University of Alberta, AB T6G 1H9, Canada
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Authors to whom correspondence should be addressed.
Metals 2018, 8(4), 229; https://doi.org/10.3390/met8040229
Received: 17 February 2018 / Revised: 30 March 2018 / Accepted: 30 March 2018 / Published: 2 April 2018
Lightweight structural applications of magnesium and aluminum alloys inevitably necessitate welding and joining, especially dissimilar welding between these alloys. The objective of this study was to examine the feasibility of joining ZEK100 Mg alloy to Al6022 alloy via ultrasonic spot welding, focusing on effects of welding energy. An interface diffusion layer consisting of α-Mg and Al12Mg17 eutectic structure was observed to form, with its thickness increased from ~0.5 µm to ~30 µm with increasing welding energy from 500 J to 2000 J. The tensile lap shear peak load or strength and critical stress intensity of the welded joints first increased and then decreased with increasing welding energy, with their peak values achieved at 750 J. Fatigue life of the joints made at 750 J and 2000 J was equivalent at the lower cyclic loading levels, while it was longer for the joints made at 750 J at the higher cyclic loading levels. Fatigue fracture mode changed from interfacial failure to mainly transverse-through-thickness crack growth with decreasing cyclic loading level, which corresponded well to the bi-linear characteristic of S-N curves. Crack initiation basically occurred at the weld nugget border and at the interface between the two sheets, which can be understood via a theoretical stress analysis. View Full-Text
Keywords: magnesium alloy; aluminum alloy; dissimilar joints; ultrasonic spot welding; microstructure; peak load; fatigue life magnesium alloy; aluminum alloy; dissimilar joints; ultrasonic spot welding; microstructure; peak load; fatigue life
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MDPI and ACS Style

Peng, H.; Jiang, X.; Bai, X.; Li, D.; Chen, D. Microstructure and Mechanical Properties of Ultrasonic Spot Welded Mg/Al Alloy Dissimilar Joints. Metals 2018, 8, 229.

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