Advertisement

A Review and Case Study on Mechanical Properties and Microstructure Evolution in Magnesium–Steel Friction Stir Welding

  • Suryakanta SahuEmail author
  • Omkar Thorat
  • Raju Prasad Mahto
  • Surjya Kanta Pal
  • Prakash Srirangam
Conference paper
First Online:
Part of the The Minerals, Metals & Materials Series book series (MMMS)

Abstract

Weight minimization and global environmental policies on carbon content open a new research avenue towards materials and manufacturing processes in transport industries. Friction stir welding (FSW) process is a combination of frictional heating and stirring action where materials are joined in their solid state. In this study, a review has been made on the joining status of magnesium alloys to steel by using FSW. Present problems and future opportunities of magnesium to steel joining with the help of FSW are also stated. A case study has also been presented where the joint characteristics of AZ31B to AISI 304 sheets fabricated in lap configuration by FSW have been investigated by varying tool rotational speed (600, 1000, and 1800 rpm) and varying weld speed (40, 200, and 350 mm/min). A maximum weld joint efficiency of 79% of the AZ31B base alloy has been achieved with a parametric combination of 600 rpm and 350 mm/min.

Keywords

Automotive industry Magnesium alloys Stainless steel Friction stir welding Dissimilar joints 
This is a preview of subscription content, log in to check access.

References

  1. 1.
    Caiwang Tan, Liqun Li, Yanbin Chen, Wei Guo, “Laser-tungsten inert gas hybrid welding of dissimilar metals AZ31B Mg alloys to Zn coated steel,” Materials and Design 49 (2013) 766–773Google Scholar
  2. 2.
    Waled M. Elthalabawy, Tahir I. Khan, “Microstructural development of diffusion-brazed austenitic stainless steel to magnesium alloy using a nickel interlayer,” Materials Characterization 61 (2010) 703–712CrossRefGoogle Scholar
  3. 3.
    Takehide Senuma, “Physical metallurgy of modern high strength steel sheets,” ISIJ International, Vol. 41 (2001), No. 6, pp. 520–532CrossRefGoogle Scholar
  4. 4.
    Prakash Kumar Sahu, Sukhomay Pal, “Influence of metallic foil alloying by FSW process on mechanical properties and metallurgical characterization of AM20 Mg alloy,” Materials Science & Engineering A 684 (2017) 442–455CrossRefGoogle Scholar
  5. 5.
    L. Liu (ed) (2010) Welding and Joining of Magnesium Alloys. Woodhead Publishing Limited, UKGoogle Scholar
  6. 6.
    V.K. Patel, S.D. Bhole and D.L. Chen, “Influence of ultrasonic spot welding on microstructure in a magnesium alloy,” Scripta Materialia 65 (2011) 911–914CrossRefGoogle Scholar
  7. 7.
    V.K. Patel, S.D. Bhole, D.L. Chen, “Formation of zinc interlayer texture during dissimilar ultrasonic spot welding of magnesium and high strength low alloy steel,” Materials and Design 45 (2013) 236–240CrossRefGoogle Scholar
  8. 8.
    W. Xua, D.L. Chena, L. Liub, H. Mori, Y. Zhoub, “Microstructure and mechanical properties of weld-bonded and resistance spot welded magnesium-to-steel dissimilar joints,” Materials Science and Engineering A 537 (2012) 11–24CrossRefGoogle Scholar
  9. 9.
    L. Liu, L. Xiao, J.C. Feng, Y.H. Tian, S.Q. Zhou, and Y. Zhou, “The Mechanisms of Resistance Spot Welding of Magnesium to Steel,” Metallurgical and Materials Transactions A, Volume 41A, October 2010, 2651–2661CrossRefGoogle Scholar
  10. 10.
    L. Liu, L. Xiao, D.L. Chen, J.C. Feng, S. Kim, Y. Zhou, “Microstructure and fatigue properties of Mg-to-steel dissimilar resistance spot welds,” Materials and Design 45 (2013) 336–342CrossRefGoogle Scholar
  11. 11.
    G. Casalinoa, P. Guglielmi, V.D. Lorusso, M. Mortello, P. Peyre, D. Sorgente, “Laser offset welding of AZ31B magnesium alloy to 316 stainless steel,” Journal of Materials Processing Technology 242 (2017) 49–59CrossRefGoogle Scholar
  12. 12.
    M. Wahba, S. Katayama, “Laser welding of AZ31B magnesium alloy to Zn-coated steel,” Materials and Design 35 (2012) 701–706CrossRefGoogle Scholar
  13. 13.
    Xiaodong Qi, Gang Song, “Interfacial structure of the joints between magnesium alloy and mild steel with nickel as interlayer by hybrid laser-TIG welding,” Materials and Design 31 (2010) 605–609Google Scholar
  14. 14.
    Liming Liu, Xiaodong Qi, “Strengthening effect of nickel and copper interlayers on hybrid laser-TIG welded joints between magnesium alloy and mild steel,” Materials and Design 31 (2010) 3960–3963Google Scholar
  15. 15.
    Gang Song, Guangye An, Liming Liu, “Effect of gradient thermal distribution on butt joining of magnesium alloy to steel with Cu–Zn alloy interlayer by hybrid laser–tungsten inert gas welding,” Materials and Design 35 (2012) 323–329Google Scholar
  16. 16.
    Zhi Zeng, Xunbo Li, Yugang Miao, Gang Wu, Zijun Zhao, “Numerical and experiment analysis of residual stress on magnesium alloy and steel butt joint by hybrid laser-TIG welding,” Computational Materials Science 50 (2011) 1763–1769CrossRefGoogle Scholar
  17. 17.
    L. M. Liu, X. Zhao, “Study on the weld joint of Mg alloy and steel by laser-GTA hybrid welding,” Materials Characterization 59 (2008) 1279–1284CrossRefGoogle Scholar
  18. 18.
    Y. G. Miao, D. F. Han, J. Z. Yao & F. Li, “Microstructure and interface characteristics of laser penetration brazed magnesium alloy and steel,” Sci. Technol. Weld. Join., vol. 15, no. 2, pp. 97–103, 2010CrossRefGoogle Scholar
  19. 19.
    C. W. Tan, Y. B. Chen, L. Q. Li & W. Guo, “Microstructure and properties of laser brazed magnesium to coated Steel,” Sci. Technol. Weld. Join., vol. 18, no. 6, pp. 466–472, 2013Google Scholar
  20. 20.
    Y. C. Chen and K. Nakata, “Effect of surface states of steel on microstructure and mechanical properties of lap joints of magnesium alloy and steel by friction stir welding,” Sci. Technol. Weld. Join., vol. 15, no. 4, pp. 293–298, 2010CrossRefGoogle Scholar
  21. 21.
    Y. C. Chen and K. Nakata, “Effect of tool geometry on microstructure and mechanical properties of friction stir lap welded magnesium alloy and steel,” Mater. Des., vol. 30, no. 9, pp. 3913–3919, 2009CrossRefGoogle Scholar
  22. 22.
    Y. C. Chen and K. Nakata, “Friction Stir Lap Welding of Magnesium Alloy and Zinc Coated Steel,” Mater. Trans., vol. 50, no. 11, pp. 2598–2603, 2009CrossRefGoogle Scholar
  23. 23.
    S. Jana and Y. Hovanski, “Fatigue behaviour of magnesium to steel dissimilar friction stir lap joints,” Sci. Technol. Weld. Join., vol. 17, no. 2, pp. 141–145, 2012CrossRefGoogle Scholar
  24. 24.
    S. Jana, Y. Hovanski, and G. J. Grant, “Friction stir lap welding of magnesium alloy to steel: A preliminary investigation,” Metall. Mater. Trans. A Phys. Metall. Mater. Sci., vol. 41, no. 12, pp. 3173–3182, 2010CrossRefGoogle Scholar
  25. 25.
    H. Kasai, Y. Morisada, H. Fujii, “Dissimilar FSW of immiscible materials: Steel/magnesium,” Materials Science & Engineering A 624 (2015) 250–255CrossRefGoogle Scholar
  26. 26.
    C. Schneider, T. Weinberger, J. Inoue, T. Koseki, and N. Enzinger, “Characterisation of interface of steel/magnesium FSW,” Sci. Technol. Weld. Join., vol. 16, no. 1, pp. 100–107, 2011CrossRefGoogle Scholar
  27. 27.
    N. Afrin, D. L. Chen, X. Cao, and M. Jahazi, “Microstructure and tensile properties of friction stir welded AZ31B magnesium alloy,” Mater. Sci. Eng. A, vol. 472, no. 1–2, pp. 179–186, 2008CrossRefGoogle Scholar
  28. 28.
    Z. Y. Ma, “Friction stir processing technology: A Review,” Metallurgical and Materials Transactions A, Volume 39A, March 2008, 642–658Google Scholar
  29. 29.
    A. Gerlich, P. Su, M. Yamamoto & T. H. North, “Material flow and intermixing during dissimilar friction stir welding,” Sci. Technol. Weld. Join., vol. 13, no. 3, pp. 254–264, 2008CrossRefGoogle Scholar
  30. 30.
    P. Su, A. Gerlich, T.H. North, and G.J. Bendzsak, “Intermixing in dissimilar friction stir spot welds,” Metallurgical and Materials Transactions A, Volume 38A, March 2007, 584–595Google Scholar
  31. 31.
    Padmanaban, G. & Balasubramanian, V, “An experimental investigation on friction stir welding of AZ31B magnesium alloy,” Int J Adv Manuf Technol (2010) 49: 111.  https://doi.org/10.1007/s00170-009-2368-1CrossRefGoogle Scholar
  32. 32.
    Y. U. Sirong, Chen Xianjun, Huang Zhiqiu, Liu Yaohui, “Microstructure and mechanical properties of friction stir welding of AZ31B magnesium alloy added with cerium,” Journal of Rare Earths, Vol. 28, No. 2, Apr. 2010, p. 316Google Scholar
  33. 33.
    B. Ratna Sunil, G. Pradeep Kumar Reddy, A.S.N. Mounika, P. Navya Sree, P. Rama Pinneswari, I. Ambica, R. Ajay Babu, P. Amarnadh, “Joining of AZ31 and AZ91 Mg alloy by friction stir welding,” Journal of Magnesium and Alloys 3 (2015) 330–334CrossRefGoogle Scholar
  34. 34.
    Stephan W. Kallee Wayne M. Thomas E. Dave Nicholas, “Friction stir welding of lightweight materials,” TWI Ltd, Cambridge, United Kingdom, pp 175–190Google Scholar
  35. 35.
    P. Cavaliere, P.P. De, “Marco Superplastic behaviour of friction stir processed AZ91 magnesium alloy produced by high pressure die cast,” Journal of Materials Processing Technology 184 (2007) 77–83CrossRefGoogle Scholar
  36. 36.
    Yajie Li, Fengming Qin, Cuirong Liu and Zhisheng Wu, “A review: Effect of friction stir welding on microstructure and mechanical properties of magnesium alloys,” Metals 2017, 7(12), 524;  https://doi.org/10.3390/met7120524
  37. 37.
    Y. Wei, J. Li, J. Xiong, F. Huang, and F. Zhang, “Microstructures and mechanical properties of magnesium alloy and stainless steel weld-joint made by friction stir lap welding,” Mater. Des., vol. 33, no. 1, pp. 111–114, 2012CrossRefGoogle Scholar
  38. 38.
    ASTM E3-11(2017) Standard Guide for Preparation of Metallographic Specimens, ASTM International, West Conshohocken, PA, 2017,  https://doi.org/10.1520/E0003-11R17
  39. 39.
    ASTM E407-07(2015)e1 Standard Practice for Microetching Metals and Alloys, ASTM International, West Conshohocken, PA, 2015,  https://doi.org/10.1520/E0407-07R15E01
  40. 40.
    ASTM E384-17 Standard Test Method for Microindentation Hardness of Materials, ASTM International, West Conshohocken, PA, 2017,  https://doi.org/10.1520/E0384-17

Copyright information

© The Minerals, Metals & Materials Society 2019

Authors and Affiliations

  • Suryakanta Sahu
    • 1
    Email author
  • Omkar Thorat
    • 2
  • Raju Prasad Mahto
    • 3
  • Surjya Kanta Pal
    • 3
  • Prakash Srirangam
    • 4
  1. 1.Advanced Technology Development CentreIndian Institute of Technology KharagpurKharagpurIndia
  2. 2.Department of Mechanical EngineeringDr. Babasaheb Ambedkar Technological UniversityRaigadIndia
  3. 3.Department of Mechanical EngineeringIndian Institute of Technology KharagpurKharagpurIndia
  4. 4.Warwick Manufacturing Group (WMG)University of WarwickCoventryUK

Personalised recommendations

Cite paper

Buy options