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<p>To enhance the weld quality of 6061-T6 aluminum alloy/AZ31B magnesium alloy joints in resistance spot welding (RSW), a novel technique has been introduced, which involves the prefabricated hole on the Al-based alloy side and its subsequent filling with Cr powder, based on the conventional welding with optimized parameter. Extensive research and analysis have revealed that the prefabricated hole process forms a self-plugging rivet structure at the joint interface, which strengthens the mechanical interlocking capability. The maximum shear strength of the joint was increased to 3715 N, marking a 24.66% enhancement over 2980 N for direct welding. Following the filling of prefabricated holes with Cr powder, a self-punching rivet-like structure composed of a mixture of Al, Mg, and Cr elements was formed. This structure significantly enhanced the metallurgical bonding capacity at the interface. Furthermore, interfacial intermetallic compounds (IMCs), including the Al₈Cr₅ and Al₁₈Cr₂Mg₃ phases, were generated. These IMCs exhibited superior ductility compared to conventional Al/Mg IMCs. Furthermore, the finer Cr powder particles readily penetrated narrow gaps within the weld joint, thereby preventing the formation of defects such as voids and enhancing joint quality. The joint attained a shear strength of 3999 N, representing a 34.19% increase over directly welded joints. Fracture surfaces displayed a limited number of dimples, indicative of a mixed-mode fracture combining both ductile and cleavage characteristics. The innovative prefabricated hole process proposed in this study offers a groundbreaking approach for fabricating cost-effective, high-quality Al/Mg resistance spot welded joints.</p>

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Microstructure and mechanical properties of resistance spot welded aluminum/magnesium joints via prefabricated hole and Cr powder filling process

  • 期刊论文

  • 发表日期：

    2025年8月9日

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  • Xinbin Hu,
  • Jingwei Fu,
  • Chuansong Xia,
  • Sheng Liu,
  • Wei Long,
  • Wuxin Zhao

摘要

To enhance the weld quality of 6061-T6 aluminum alloy/AZ31B magnesium alloy joints in resistance spot welding (RSW), a novel technique has been introduced, which involves the prefabricated hole on the Al-based alloy side and its subsequent filling with Cr powder, based on the conventional welding with optimized parameter. Extensive research and analysis have revealed that the prefabricated hole process forms a self-plugging rivet structure at the joint interface, which strengthens the mechanical interlocking capability. The maximum shear strength of the joint was increased to 3715 N, marking a 24.66% enhancement over 2980 N for direct welding. Following the filling of prefabricated holes with Cr powder, a self-punching rivet-like structure composed of a mixture of Al, Mg, and Cr elements was formed. This structure significantly enhanced the metallurgical bonding capacity at the interface. Furthermore, interfacial intermetallic compounds (IMCs), including the Al₈Cr₅ and Al₁₈Cr₂Mg₃ phases, were generated. These IMCs exhibited superior ductility compared to conventional Al/Mg IMCs. Furthermore, the finer Cr powder particles readily penetrated narrow gaps within the weld joint, thereby preventing the formation of defects such as voids and enhancing joint quality. The joint attained a shear strength of 3999 N, representing a 34.19% increase over directly welded joints. Fracture surfaces displayed a limited number of dimples, indicative of a mixed-mode fracture combining both ductile and cleavage characteristics. The innovative prefabricated hole process proposed in this study offers a groundbreaking approach for fabricating cost-effective, high-quality Al/Mg resistance spot welded joints.