Journal ArticleDOI
Ultrasonic spot welding of rare-earth containing ZEK100 magnesium alloy to 5754 aluminum alloy
A. Macwan,Daolun Chen +1 more
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In this paper, the feasibility of joining a low rare earth containing ZEK100 Mg alloy to 5754 Al alloy via solid-state ultrasonic spot welding (USW), and evaluate the interface microstructure, tensile lap shear strength, and fatigue life.Abstract:
The aim of this study was to examine the feasibility of joining a low rare-earth containing ZEK100 Mg alloy to 5754 Al alloy via solid-state ultrasonic spot welding (USW), and evaluate the interface microstructure, tensile lap shear strength, and fatigue life. A diffusion layer consisting of eutectic structure of α-Mg and Al12Mg17 intermetallic compound was observed to form at the interface during USW, and its thickness increased with increasing welding energy. The tensile lap shear strength first increased, reached a peak value and then decreased with increasing welding energy. The optimal average strength of ZEK100-Al5754 dissimilar joints arrived at ~78% of ZEK100-ZEK100 similar joints and ~55% of Al5754-Al5754 similar joints. The tensile lap shear test samples failed in an interfacial mode with partial cohesive failure through the interface diffusion layer and partial failure through Mg alloy, with Mg alloy sticking on the Al side. Fatigue life of samples welded at a welding energy of 500 J was longer than that at 1000 J at higher cyclic loading levels, and it became equivalent at lower cyclic loading levels. The bi-linear behavior of S-N curves corresponded well to the change in the failure characteristics. At higher cyclic loading levels interfacial failure prevailed, while the formation of transverse-through-thickness (TTT) crack at the nugget edge occurred at lower cyclic loading levels.read more
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Ultrasonic spot welded 6111-T4 aluminum alloy to galvanized high-strength low-alloy steel: Microstructure and mechanical properties
A. Macwan,Asit Kumar,Daolun Chen +2 more
TL;DR: In this article, solid-state ultrasonic spot welding (USW) was used to join Al alloy 6111-T4 to galvanized high-strength low-alloy (HSLA) steel at different welding energy levels.
Journal ArticleDOI
Effect of welding energy on microstructure and strength of ultrasonic spot welded dissimilar joints of aluminum to steel sheets
TL;DR: In this paper, two dissimilar ultrasonic spot welded joints of aluminum to commercial steel sheets at different levels of welding energy were investigated, and tensile lap shear tests were conducted to evaluate the failure strength in relation to microstructural changes.
Journal ArticleDOI
Impact of ultrasonic welding on multi-layered Al–Cu joint for electric vehicle battery applications: A layer-wise microstructural analysis
Sisir Dhara,Abhishek Das +1 more
TL;DR: In this paper, three layers of Al tabs were welded to 10mm single Cu busbar for the investigations of multi-layered Al-Cu dissimilar joints Joint macro and microstructures, welding mechanism, layer-wise micro-hardness and grain formation were studied to understand the flow of material, the formation of grains and mixing of the Al and Cu for underweld, good-weld and overweld categories The effects of amplitude of ultrasonic vibration, welding pressure and welding time were investigated to produce the satisfactory tab-to-busbar connection.
Journal ArticleDOI
Microstructure and mechanical properties of Mg/Al joints welded by ultrasonic spot welding with Zn interlayer
TL;DR: In this paper, the interfacial layer forming, microstructure, mechanical properties and fracture mechanisms of the Mg/Zn/Al ultrasonic spot welded (USWed) joints were studied systematically.
Journal ArticleDOI
Microstructure and mechanical properties of Mg-to-Al dissimilar welded joints with an Ag interlayer using ultrasonic spot welding
TL;DR: In this article, a lightweight ZEK100-O Mg alloy and Al6022-T43 Al alloy with an Ag interlayer were joined via ultrasonic spot welding (USW), focusing on the microstructural change and tensile lap shear strength of the welded joints in relation to welding energy.
References
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J.E. Gray,B. Luan +1 more
TL;DR: In this paper, the state of the art in coating and surface modification technologies, applied to magnesium-based substrates for improved corrosion and wear resistance, are discussed, including electrochemical plating, conversion coatings, anodizing, gas phase deposition processes, laser surface alloying/cladding and organic coatings.
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A high-specific-strength and corrosion-resistant magnesium alloy
Wanqiang Xu,Wanqiang Xu,Nick Birbilis,Nick Birbilis,Gang Sha,Yu Wang,John E. Daniels,Yang Xiao,Michael Ferry,Michael Ferry +9 more
TL;DR: An ultralow density (1.4 g cm(-3)) Mg-Li-based alloy is designed that is strong, ductile, and more corrosion resistant than M g-based alloys reported so far.
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The origins of high hardening and low ductility in magnesium
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