At present aluminium-magnesium alloys are widely used in various engineering applications due to its light weight and superior properties. Joining is considered as one of the most complex phenomenon in various precision industries like aerospace, railway, automotive and marine structures because inflexible tolerances are required during different product assembly. The friction stir welding (FSW) of aluminium-magnesium of various grade has incited substantial scientific and industrial importance since it has a potency to transform the product with a good quality joint. The fabrication of such alloys is a challenging task through conventional fusion welding due to its various metallurgical concerns. Therefore, the present work is intended to summarize the recent progress in FSW of aluminium-magnesium alloys. Particular attention has been paid to microstructural evolution, phase transformation, recrystallization mechanism, material flow behaviour and how the process parameters influence the various mechanical properties and associated defects during FSW. Various experimental and numerical simulation results have been mentioned for weld property comparison. Finally, this work not only points out the prominent conclusions of the preceding research but also recommends the upcoming guidance concerning to fabrication of aluminium-magnesium alloys through FSW.

Recent research progress in solid state friction-stir welding of aluminium–magnesium alloys: a critical review

The paper critically assesses the research progress towards aluminium–magnesium dissimilar friction stir welding (FSW). First, the theoretical requirements are explored through the understanding of joining mechanism and heat generation in aluminium–magnesium FSW. Next, the observed trends in microstructural characterisation and mechanical properties are analysed. Finally, the effects of welding parameters and how it influences process variables and materials responses are discussed in detail, and several suggestions are made based on these discussions.

Review of research progress on aluminium–magnesium dissimilar friction stir welding

Friction stir welding is a rather recent welding process (patented in 1991 by Thomas et al., ‘Improvements to friction welding’ UK patent application no. 9125978.8, US Patent 5460317, 1995) that has shown great potential for welding dissimilar materials even of different metallic nature, e.g. Al to steel, Mg to steel, Al to Ti, Mg to Ti, Al to Cu, Al to Mg. This review presents the specific microstructural features and mechanical properties, in particular tensile strength, of such welds. A focus will be on the material flow and welding defects, on the intermetallic compounds, on constitutional liquation, on particularities related to dissimilar lap welding and finally on process modifications to improve dissimilar friction stir weldability.

State of the art about dissimilar metal friction stir welding

Effects of process parameters on microstructure and mechanical properties of friction stir lap linear welded 6061 aluminum alloy to NZ30K magnesium alloy

Mingchao Guo

Papers

Fatigue and fracture of friction stir linear welded dissimilar aluminum-to-magnesium alloys

A Fatigue Life Estimation Technique for Body Mount Joints

Fatigue Based Lightweight Optimization of a Pickup Cargo Box with Advanced High Strength Steels

Failure Modeling of Adhesive Bonded Joints with Cohesive Elements

A Fatigue Life Prediction Method of Laser Assisted Self-Piercing Rivet Joint for Magnesium Alloys