Top

Journal of Materials Engineering and Performance

Published in:

13-09-2021

Effect of Susceptors on Joining of AA6061-T6 to AZ31B by Microwave Hybrid Heating

Authors: S. Tamang, S. Aravindan

Published in: Journal of Materials Engineering and Performance | Issue 2/2022

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

The joining of aluminum (Al) to magnesium (Mg) alloys is a challenge due to the detrimental effects of formation of hard and brittle intermetallic compounds. This work investigates the joining of AA6061-T6 to AZ31B by microwave hybrid heating using zinc (Zn) powder, especially in the effect of susceptors on microstructure. It was observed that formation of Al-Mg intermetallic compounds was hindered, and a good metallurgical joint was achieved. A distinct reaction zone was formed between the Zn interlayer and AZ31B. The use of graphite susceptor exhibited faster joint formation than when activated charcoal was used. However, graphite susceptor formed irregular reaction zone, whereas activated charcoal produced an uniform reaction zone. Elemental analysis concluded the formation of a solid solution of Mg + MgZn on the reaction zone. The width of the Mg-Zn reaction layer increased with the increase in microwave exposure time. Toward the AA6061- Zn faying surface of the interlayer, a Zn solid solution was formed having no intermetallic compounds and no reaction layer. Zn solid solution zone compromised the mechanical strength of the joint. The optimum value of microwave exposure time, clamping pressure and epoxy% was studied to achieve the highest joint strength.

previous article Tribological Properties and Friction-Induced Noise Performance of M50 with Curved Microchannels Filled by Sn-Ag-Cu and Ti3C2

next article Fabrication and Characterization of Nickel Microtubes through Electroforming: Deposition Optimization Using Evolutionary Algorithms

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

L. Berger, M. Lesemann, and C. Sahr, “SuperLIGHT-CAR – the Multi-Material Car Body,” 7th European LS-DYNA Conference, 2009, p 1–10, https://www.dynamore.de/de/download/papers/forum08/dokumente/F-III-01.pdf.

E. Schubert, M. Klassen, I. Zerner, C. Walz and G. Sepold, Light-Weight Structures Produced by Laser Beam Joining for Future Applications in Automobile and Aerospace Industry, J. Mater. Process. Technol., 2001, 115(1), p 2–8. CrossRef

L.P. Troeger and E. a. Starke, Microstructural and Mechanical Characterization of a Superplastic 6xxx Aluminum Alloy, Mater. Sci. Eng. A, 2000, 277(1–2), p 102–113.

B.L. Mordike and T. Ebert, Magnesium Properties - Applications - Potential, Mater. Sci. Eng. A, 2001, 302(1), p 37–45. CrossRef

C. Moosbrugger, Introduction to Magnesium Alloys, Engineering Properties of Magnesium Alloys, ASM International®, 2017, www.asminternational.org.

L. Peng, L. Yajiang, G. Haoran and W. Juan, A Study of Phase Constitution near the Interface of Mg/Al Vacuum Diffusion Bonding, Mater. Lett., 2005, 59(16), p 2001–2005. CrossRef

M. Joseph Fernandus, T. Senthilkumar, V. Balasubramanian and S. Rajakumar, Optimizing Diffusion Bonding Parameters in AA6061-T6 Aluminum and AZ80 Magnesium Alloy Dissimilar Joints, J. Mater. Eng. Perform., 2012, 21(11), p 2303–2315. CrossRef

R. Borrisutthekul, Y. Miyashita and Y. Mutoh, Dissimilar Material Laser Welding Between Magnesium Alloy AZ31B and Aluminum Alloy A5052-O, Sci. Technol. Adv. Mater., 2005, 6, p 199–204. CrossRef

H.-Y. Wang, L.-M. Liu, M.-L. Zhu and H. Wang, Laser Weld Bonding of A6061Al Alloy to AZ31B Mg Alloy, Sci. Technol. Weld. Join., 2007, 12(3), p 261–265. https://doi.org/10.1179/174329307X159784CrossRef

10.

F. Hayat, The Effects of the Welding Current on Heat Input, Nugget Geometry, and the Mechanical and Fractural Properties of Resistance Spot Welding on Mg/Al Dissimilar Materials, Mater. Des., 2011, 32(4), p 2476–2484. CrossRef

11.

P. Liu, Y. Li, H. Geng and J. Wang, Microstructure Characteristics in TIG Welded Joint of Mg/Al Dissimilar Materials, Mater. Lett., 2007, 61(6), p 1288–1291. CrossRef

12.

H.Y. Wang, L.M. Liu and Z.Y. Jia, The Influence of Adhesive on the Al Alloy in Laser Weld Bonding Mg – Al Process, J. Mater. Sci., 2011, 46, p 5534–5540. CrossRef

13.

Y. Li, P. Liu, J. Wang and H. Ma, XRD and SEM Analysis near the Diffusion Bonding Interface of Mg/Al Dissimilar Materials, Vacuum, 2007, 82(1), p 15–19. CrossRef

14.

B. Fu, G. Qin, F. Li, X. Meng, J. Zhang and C. Wu, Friction Stir Welding Process of Dissimilar Metals of 6061-T6 Aluminum Alloy to AZ31B Magnesium Alloy, J. Mater. Process. Technol., 2015, 218, p 38–47. https://doi.org/10.1016/j.jmatprotec.2014.11.039CrossRef

15.

V. Firouzdor and S. Kou, Formation of Liquid and Intermetallics in Al-to-Mg Friction Stir Welding, Metall. Mater. Trans. A, 2010, 41(12), p 3238–3251. https://doi.org/10.1007/s11661-010-0366-4CrossRef

16.

K. Yin, L. Cao and N. Wang, Mechanical Properties and Residual Stresses of 5083 to AM60B Dissimilar Friction Stir Welding with Different Process Parameters, J. Adhes. Sci. Technol., 2019, 33(23), p 2615–2629. https://doi.org/10.1080/01694243.2019.1653593CrossRef

17.

S. Kumar and C. Wu, Suppression of Intermetallic Reaction Layer by Ultrasonic Assistance during Friction Stir Welding of Al and Mg Based Alloys, J. Alloys Compd., 2020, 827, p 154343. https://doi.org/10.1016/j.jallcom.2020.154343CrossRef

18.

F. Liu, Z. Zhang and L. Liu, Microstructure Evolution of Al/Mg Butt Joints Welded by Gas Tungsten Arc with Zn Filler Metal, Mater. Charact., 2012, 69, p 84–89. CrossRef

19.

H.T. Zhang and J.Q. Song, Microstructural Evolution of Aluminum/Magnesium Lap Joints Welded Using MIG Process with Zinc Foil as an Interlayer, Mater. Lett., 2011, 65(21–22), p 3292–3294. https://doi.org/10.1016/j.matlet.2011.05.080CrossRef

20.

H.T. Zhang, X.Y. Dai and J.C. Feng, Joining of Aluminum and Magnesium via Pre-Roll-Assisted A-TIG Welding with Zn Interlayer, Mater. Lett., 2014, 122, p 49–51. https://doi.org/10.1016/j.matlet.2014.02.008CrossRef

21.

Y. Zhang, Z. Luo, Y. Li, Z. Liu and Z. Huang, Microstructure Characterization and Tensile Properties of Mg/Al Dissimilar Joints Manufactured by Thermo-Compensated Resistance Spot Welding with Zn Interlayer, Mater. Des., 2015, 75, p 166–173. https://doi.org/10.1016/j.matdes.2015.03.030CrossRef

22.

L. Liu, J. Tan and X. Liu, Reactive Brazing of Al Alloy to Mg Alloy Using Zinc-Based Brazing Alloy, Mater. Lett., 2007, 61(11–12), p 2373–2377. CrossRef

23.

L.M. Zhao and Z.D. Zhang, Effect of Zn Alloy Interlayer on Interface Microstructure and Strength of Diffusion-Bonded Mg-Al Joints, Scr. Mater., 2008, 58(4), p 283–286. CrossRef

24.

L.M. Liu, J.H. Tan, L.M. Zhao and X.J. Liu, The Relationship between Microstructure and Properties of Mg/Al Brazed Joints Using Zn Filler Metal, Mater. Charact., 2008, 59(4), p 479–483. CrossRef

25.

R. Gan and Y. Jin, Friction Stir-Induced Brazing of Al/Mg Lap Joints with and without Zn Interlayer, Sci. Technol. Weld. Join., 2018, 23(2), p 164–171. https://doi.org/10.1080/13621718.2017.1354545CrossRef

26.

A. Abdollahzadeh, A. Shokuhfar, J.M. Cabrera, A.P. Zhilyaev and H. Omidvar, The Effect of Changing Chemical Composition in Dissimilar Mg/Al Friction Stir Welded Butt Joints Using Zinc Interlayer, J. Manuf. Process., 2018, 34, p 18–30. https://doi.org/10.1016/j.jmapro.2018.05.029CrossRef

27.

L.M. Liu, L.M. Zhao and R.Z. Xu, Effect of Interlayer Composition on the Microstructure and Strength of Diffusion Bonded Mg / Al Joint, Mater. Des., 2009, 30(10), p 4548–4551. https://doi.org/10.1016/j.matdes.2009.04.040CrossRef

28.

R.Z. Xu, D.R. Ni, Q. Yang, C.Z. Liu and Z.Y. Ma, Influence of Zn Coating on Friction Stir Spot Welded Magnesium-Aluminium Joint, Sci. Technol. Weld. Join., 2016, 1718, p 1–8. https://doi.org/10.1080/13621718.2016.1266735CrossRef

29.

M. Li, C. Zhang, D. Wang, L. Zhou, D. Wellmann and Y. Tian, Friction Stir Spot Welding of Aluminum and Copper: A Review, Mater. Basel., 2020, 13(1), p 156.

30.

H. Zhao, G. Zhang, Q. Zhang, C. Zhang and Y. Li, Joining Mechanism and Mechanical Properties of Metallic Bump Assisted Weld-Bonded (MBaWB) Joints of AA6061-T6 and Bare DP590, J. Manuf. Process., 2019, 2020(50), p 204–215. https://doi.org/10.1016/j.jmapro.2019.12.018CrossRef

31.

M. Gupta and W.W. Leong, Microwaves and Metals. Wiley, New York, 2007, https://doi.org/10.1002/9780470822746.

32.

S. Chandrasekaran, T. Basak and S. Ramanathan, Experimental and Theoretical Investigation on Microwave Melting of Metals, J. Mater. Process. Technol., 2011, 211(3), p 482–487. https://doi.org/10.1016/j.jmatprotec.2010.11.001CrossRef

33.

D.C. Dube, P.D. Ramesh, J. Cheng, M.T. Lanagan, D. Agrawal and R. Roy, Experimental Evidence of Redistribution of Fields during Processing in a High-Power Microwave Cavity, Appl. Phys. Lett., 2004, 85(16), p 3632–3634. CrossRef

34.

E. Siores and D.D. Rego, Microwave Applications in Materials Joining, J. Mater. Process. Technol., 1995, 48(1–4), p 619–625. CrossRef

35.

S. Singh, D. Gupta and V. Jain, Recent Applications of Microwaves in Materials Joining and Surface Coatings, Proc. Inst. Mech. Eng. Part J. Eng. Manuf., 2015 https://doi.org/10.1177/0954405414560778CrossRef

36.

C. Leonelli, P. Veronesi, L. Denti, A. Gatto and L. Iuliano, Microwave Assisted Sintering of Green Metal Parts, J. Mater. Process. Technol., 2008, 205(1–3), p 489–496. https://doi.org/10.1016/j.jmatprotec.2007.11.263CrossRef

37.

R. Roy, D. Agrawal, J. Cheng and S. Gedevanlshvili, Full Sintering of Powdered-Metal Bodies in a Microwave Field, Nature, 1999, 399(6737), p 668–670. https://doi.org/10.1038/21390CrossRef

38.

K. Rajkumar and S. Aravindan, Microwave Sintering of Copper-Graphite Composites, J. Mater. Process. Technol., 2009, 209(15–16), p 5601–5605. CrossRef

39.

M.S. Srinath, A.K. Sharma and P. Kumar, A New Approach to Joining of Bulk Copper Using Microwave Energy, Mater. Des., 2011, 32(5), p 2685–2694. https://doi.org/10.1016/j.matdes.2011.01.023CrossRef

40.

R.I. Badiger, S. Narendranath and M.S. Srinath, Joining of Inconel-625 Alloy through Microwave Hybrid Heating and Its Characterization, J. Manuf. Process., 2015, 18, p 117–123. https://doi.org/10.1016/j.jmapro.2015.02.002CrossRef

41.

A. Bansal, A.K. Sharma, P. Kumar and S. Das, Characterization of Bulk Stainless Steel Joints Developed through Microwave Hybrid Heating, Mater. Charact., 2014, 91, p 34–41. https://doi.org/10.1016/j.matchar.2014.02.005CrossRef

42.

P. Gupta and S. Kumar, Investigation of Stainless Steel Joint Fabricated Through Microwave Energy, Mater. Manuf. Process., 2014, 29, p 910–915. https://doi.org/10.1080/10426914.2014.892975CrossRef

43.

S. Singh, R. Singh, D. Gupta and V. Jain, Preliminary Metallurgical and Mechanical Investigations of Microwave Processed Hastelloy Joints, J. Manuf. Sci. Eng., 2017, 139(6), p 064503. https://doi.org/10.1115/1.4035370CrossRef

44.

M.S. Srinath, A.K. Sharma and P. Kumar, A Novel Route for Joining of Austenitic Stainless Steel (SS-316) Using Microwave Energy, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 2011, 225(7), p 1083–1091. https://doi.org/10.1177/2041297510393451CrossRef

45.

A. Bansal, A.K. Sharma and P. Kumar, Galvanic Corrosion Behavior of Microwave Welded and Post-Weld Heat-Treated Inconel-718 Joints, J. Mater. Eng. Perform., 2017, 26(5), p 2322–2330. CrossRef

46.

S. Tamang and S. Aravindan, Brazing of CBN to WC-Co by Ag-Cu-In-Ti Alloy through Microwave Hybrid Heating for Cutting Tool Application, Mater. Lett., 2019, 254.

47.

M.S. Srinath, A.K. Sharma and P. Kumar, Investigation on Microstructural and Mechanical Properties of Microwave Processed Dissimilar Joints, J. Manuf. Process., 2011, 13(2), p 141–146. https://doi.org/10.1016/j.jmapro.2011.03.001CrossRef

48.

A. Bansal, A.K. Sharma, S. Das, and P. Kumar, On Microstructure and Strength Properties of Microwave Welded Inconel 718/Stainless Steel (SS-316L), Proc. Inst. Mech. Eng. Part L J. Mater. Des. Appl., 2015, 0(0), p 1–10.

49.

R. Rosa, E. Colombini, P. Veronesi, G. Poli and C. Leonelli, Microwave Ignited Combustion Synthesis as a Joining Technique for Dissimilar Materials, J. Mater. Eng. Perform., 2012, 21(5), p 725–732. CrossRef

50.

S. Tamang and S. Aravindan, An Investigation on Joining of Al6061-T6 to AZ31B by Microwave Hybrid Heating Using Active Braze Alloy as an Interlayer, J. Manuf. Process., 2017, 28, p 94–100. CrossRef

51.

J.A. Menéndez, A. Arenillas, B. Fidalgo, Y. Fernández, L. Zubizarreta, E.G. Calvo and J.M. Bermúdez, Microwave Heating Processes Involving Carbon Materials, Fuel Process. Technol., 2010, 91(1), p 1–8. https://doi.org/10.1016/J.FUPROC.2009.08.021CrossRef

52.

C. Zhang, J.D. Robson, S.J. Haigh and P.B. Prangnell, Interfacial Segregation of Alloying Elements During Dissimilar Ultrasonic Welding of AA6111 Aluminum and Ti6Al4V Titanium, Metall. Mater. Trans. A Phys. Metall. Mater. Sci., 2019, 50(11), p 5143–5152. https://doi.org/10.1007/s11661-019-05395-7CrossRef

53.

S. Chandrasekaran, T. Basak and R. Srinivasan, Microwave Heating Characteristics of Graphite Based Powder Mixtures, Int. Commun. Heat Mass Transf., 2013, 48, p 22–27. https://doi.org/10.1016/j.icheatmasstransfer.2013.09.008CrossRef

54.

J.A. Menéndez, E.J. Juárez-Pérez, E. Ruisánchez, J.M. Bermúdez and A. Arenillas, Ball Lightning Plasma and Plasma Arc Formation during the Microwave Heating of Carbons, Carbon N. Y., 2011, 49(1), p 346–349. https://doi.org/10.1016/j.carbon.2010.09.010CrossRef

55.

C.A. Pickles, Microwaves in Extractive Metallurgy: Part 1 - Review of Fundamentals, Miner. Eng., 2009, 22(13), p 1102–1111. https://doi.org/10.1016/j.mineng.2009.02.015CrossRef

56.

D. Demirskyi, D. Agrawal and A. Ragulya, Densification Kinetics of Powdered Copper under Single-Mode and Multimode Microwave Sintering, Mater. Lett., 2010, 64(13), p 1433–1436. CrossRef

57.

H. Baker, “Alloy Phase Diagrams,” ASM Handbook, ASM International, 1998.

58.

A. Prince, Alloy Phase Equilibria, Elsevier, Amsterdam, 1966.CrossRef

59.

C.Q. Zhang and W. Liu, Abnormal Effect of Temperature on Intermetallic Compound Layer Growth at Aluminum-Titanium Interface: The Role of Grain Boundary Diffusion, Mater. Lett., 2019, 254, p 1–4. https://doi.org/10.1016/j.matlet.2019.07.013CrossRef

60.

F. Xu, Y. Li, X. Hu, Y. Niu, J. Zhao and Z. Zhang, In Situ Investigation of Metal’s Microwave Sintering, Mater. Lett., 2012, 67(1), p 162–164. https://doi.org/10.1016/j.matlet.2011.09.052CrossRef

61.

M. Oghbaei and O. Mirzaee, Microwave versus Conventional Sintering: A Review of Fundamentals, Advantages and Applications, J. Alloys Compd., 2010, 494(1–2), p 175–189. https://doi.org/10.1016/j.jallcom.2010.01.068CrossRef

62.

F. Porter, Zinc Handbook: Properties, Processing, and Use in Design Mechanical Engineering, CRC Press, Cambridge, 1991.CrossRef

Title: Effect of Susceptors on Joining of AA6061-T6 to AZ31B by Microwave Hybrid Heating
Authors: S. Tamang
S. Aravindan
Publication date: 13-09-2021
Publisher: Springer US
Published in: Journal of Materials Engineering and Performance / Issue 2/2022
Print ISSN: 1059-9495
Electronic ISSN: 1544-1024
DOI: https://doi.org/10.1007/s11665-021-06220-2

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 2/2022

Enhancement in Anti-Corrosive Behavior of Ni-P Coatings by Incorporation of Carbon Nanotubes

A Non-invasive Technique to Estimate the Onset of Creep Strength Deterioration

Polymer Brush Induced Electroless Copper Plating on PA12 Surface for Tensile Strength Enhancement of Selective Laser Sintering Part

Super-Hydrophobic Nanostructured Silica Coating on Aluminum Substrate for Moist Air Condensation

Laser Cladding on Copper with Composite Powder C-Al2O3-Cu

Influence of Electrolyte Compositions and Electrical Parameters on Thermal Properties of Micro-Arc Oxidized AZ91 Alloy

Premium Partners