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<p>The formation of brittle Al-Mg intermetallic compounds (IMCs) remains a key challenge for refill friction stir spot welding (RFSSW) of Al/Mg dissimilar alloys. This study aims to clarify the role of a cold-sprayed Zn interlayer in regulating interfacial reactions under various plunge depths. Dissimilar Al/Mg RFSSW welds were fabricated using 6061-T6 aluminum and AZ31 magnesium alloys. The microstructural evolution and elemental distribution at the Al/Mg interface were examined via rapid stop experiments, combined with optical microscopy (OM), scanning electron microscope (SEM), energy-dispersive spectroscopy and x-ray diffraction. Results indicated that the Zn interlayer effectively suppresses Al-Mg IMCs when the plunge depth is properly controlled. Optimal plunge depths promoted the diffusion of Zn, facilitated the formation of beneficial Al-Zn solid solutions and Mg-Zn IMCs and thus enhanced joint strength. In contrast, excessive plunge depths induced excessive heat and material flow, accelerating Al-Mg IMC formation and degrading joint quality. Insufficient plunge depths resulted in limited Zn diffusion, reducing the thickness of the metallurgical reaction layer and weakening bonding strength. These findings demonstrate that precise control of plunge depth is essential for optimizing interfacial reactions and improving mechanical performance of Al/Mg dissimilar refill friction stir spot welds.</p>

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Role of Zinc Interlayer Reactions on Mechanical Performance of Al/Mg Dissimilar Refill Friction Stir Spot Welds

  • 期刊论文

  • 发表日期：

    2025年9月5日

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  • Y. Yang,
  • Z. Shen,
  • W. Hou,
  • Z. Piao,
  • X. Liu,
  • Y. Guo,
  • G. Huang,
  • X. C. Liu,
  • P. Zhou,
  • H. Li,
  • W. Y. Li

摘要

The formation of brittle Al-Mg intermetallic compounds (IMCs) remains a key challenge for refill friction stir spot welding (RFSSW) of Al/Mg dissimilar alloys. This study aims to clarify the role of a cold-sprayed Zn interlayer in regulating interfacial reactions under various plunge depths. Dissimilar Al/Mg RFSSW welds were fabricated using 6061-T6 aluminum and AZ31 magnesium alloys. The microstructural evolution and elemental distribution at the Al/Mg interface were examined via rapid stop experiments, combined with optical microscopy (OM), scanning electron microscope (SEM), energy-dispersive spectroscopy and x-ray diffraction. Results indicated that the Zn interlayer effectively suppresses Al-Mg IMCs when the plunge depth is properly controlled. Optimal plunge depths promoted the diffusion of Zn, facilitated the formation of beneficial Al-Zn solid solutions and Mg-Zn IMCs and thus enhanced joint strength. In contrast, excessive plunge depths induced excessive heat and material flow, accelerating Al-Mg IMC formation and degrading joint quality. Insufficient plunge depths resulted in limited Zn diffusion, reducing the thickness of the metallurgical reaction layer and weakening bonding strength. These findings demonstrate that precise control of plunge depth is essential for optimizing interfacial reactions and improving mechanical performance of Al/Mg dissimilar refill friction stir spot welds.