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<p>Joining of dissimilar AZ31 Mg alloy and Cu- 8Zn alloy by using zinc interlayer through Friction Stir Welding (FSW) has been studied for the first time. The process parameters include 1200 rpm rotational speed and 20 mm/min traverse speed. Microstructural characterizations were performed to study material flow behavior, grain refinement and IMCs formation whereas, mechanical characterization includes hardness and tensile tests. SEM EDS and XRD were used for identification of phases and fracture behavior. The study revealed that for direct joining of Mg/Cu, the stir zone (SZ) mainly consisted of two-phase region containing δ-Mg and Mg<sub>2</sub>Cu along with fragments of Cu particles. Small amount of MgCu<sub>2</sub> was also observed in the form of intercalated layer along with Cu. Voids and tunnelling defects were also observed. On the other hand, the application of Zn interlayer has completely modified the structure of SZ which contains well distributed mixture of δ-Mg and MgZn. A very thin layer of MgZn<sub>2</sub> and MgO was observed in the SZ. Average tensile strength of Mg/Cu with Zn interlayer has improved to 93 MPa which is the highest joint strength as compared to the previously reported joint strength of Mg/Cu weld.</p>

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Effect of Zn interlayer on joint characteristics of dissimilar friction stir welding of Mg and Cu alloy

  • 期刊论文

  • 发表日期：

    2025年4月14日

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  • Abhijeet Bhowmik,
  • Satya Kumar Dewangan,
  • Pragya Nandan Banjare,
  • Manoranjan Kumar Manoj

摘要

Joining of dissimilar AZ31 Mg alloy and Cu- 8Zn alloy by using zinc interlayer through Friction Stir Welding (FSW) has been studied for the first time. The process parameters include 1200 rpm rotational speed and 20 mm/min traverse speed. Microstructural characterizations were performed to study material flow behavior, grain refinement and IMCs formation whereas, mechanical characterization includes hardness and tensile tests. SEM EDS and XRD were used for identification of phases and fracture behavior. The study revealed that for direct joining of Mg/Cu, the stir zone (SZ) mainly consisted of two-phase region containing δ-Mg and Mg2Cu along with fragments of Cu particles. Small amount of MgCu2 was also observed in the form of intercalated layer along with Cu. Voids and tunnelling defects were also observed. On the other hand, the application of Zn interlayer has completely modified the structure of SZ which contains well distributed mixture of δ-Mg and MgZn. A very thin layer of MgZn2 and MgO was observed in the SZ. Average tensile strength of Mg/Cu with Zn interlayer has improved to 93 MPa which is the highest joint strength as compared to the previously reported joint strength of Mg/Cu weld.