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Friction Stir Welding of Dissimilar AA7075-T6 to

AZ31B-H24 Alloys

Article  in  MRS Advances · December 2017

DOI: 10.1557/adv.2017.609

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 MRS Advances © 2017 Materials Research Society
DOI: 10.1557/adv.2017.609

Friction Stir Welding of Dissimilar AA7075-T6 to

AZ31B-H24 Alloys

D. Hernández-García1, R. Saldaña-Garcés2, F. García-Vázquez3, E.J. Gutiérrez-Castañeda4, R.

Deaquino-Lara5, D. Verdera6

1
Corporación Mexicana de Investigación en Materiales (COMIMSA). Ciencia y tecnología No. 790, Col.
Saltillo 400, Saltillo, Coahuila, México.

2
CONACYT-Corporación Mexicana de Investigación en Materiales (COMIMSA). Ciencia y tecnología
No. 790, Col. Saltillo 400, Saltillo, Coahuila, México.

3
Universidad Autónoma de Coahuila, Facultad de Ingeniería, Arteaga, Coahuila, México.

4
Catedrático CONACYT-Instituto de Metalurgia de la Universidad Autónoma de San Luis Potosí
(UASLP), Av. Sierra Leona, No. 550, Lomas 2a. Sección, San Luis Potosí, San Luis Potosí, 78210.
México.

5
Centro de Investigación y de Estudios Avanzados (CINVESTAV) Unidad Saltillo, Ramos
Arizpe, Coah., México 25900.

6
Centro Tecnológico AIMEN, Relva 27A-Torneiros, 36410, Porriño, Pontevedra, España.

Abstract

In the present investigation, AA7075-T6 alloys and AZ31B-H24 were joined by the FSW
process using the following range of parameters: rotational speed between 200 and 800 rpm,
welding speed from 30 to 60 mm/min and a tilt angle from 1° to 3°. In some cases, a tool
offset of 1 mm was used into Mg-based alloy. The experimental results show that sound and
good joints can be obtained by positioning the tool in the middle of the joint-line using a
rotational speed of 200 rpm, a welding speed of 30 mm/min and a tool tilt angle of 1°. The
hardness and ultimate tensile strength in the stir zone were 122 Hv and 61.35 MPa,
respectively. Also, it is important to mention that the Al 3Mg2 and Al12Mg17 intermetallics
compounds were observed in the this zone besides some defects like cavities and tunnel.

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 Introduction

Aluminum and magnesium alloys are lightweight construction materials that

have increased their utilization in applications within the automotive and aerospace
industries [1], due to its excellent combination of low weight and high mechanical
strength [2]. Fusion welding processes employ high temperatures that melts the materials
and then solidifies them to form the welded joint, so that the final weld has a casting
structure that decreases the mechanical properties of the joint and producing some
defects related to solidification such as porosity, oxidation, micro-segregation, hot-
cracking [3, 4] besides forming Al3Mg2 and Al12Mg17 intermetallic compounds (IMC)
in the melting zone [5]. The friction stir welding (FSW) is a solid-state technique that
offers a high-quality joint because are used temperatures below the melting point of the
materials, avoiding the formation of the aforementioned defects and obtaining a lower
formation of IMC [6]. Recent studies have used this process to weld dissimilar materials
like aluminum and magnesium alloys [7-10]. In several analysis, it has been determined
that some of the process parameters, like rotational and welding speeds, axial force,
among others, are varied in function of improving the microstructure and mechanical
properties, so according to the above the aim of this study is based on the investigation of
the mechanical and microstructural behavior when dissimilar joints of AA7075-T6 and
AZ31B-H24 alloys by the friction stir welding process were carried out, using FSW.

Experiment

In this study, plates of AA7075-T6 and AZ31B-H24 alloys with

dimensions of 150 x 60 x 6 mm were used. Their chemical compositions and mechanical
properties are shown in Table I.

Table I. Chemical compositions and mechanical properties of base metals.

Chemical composition (wt.%)
Al Mg Zn Fe Cu Mn Si Cr Ti

AA7075-T6 Bal. 2.13 5.31 0.24 1.93 0.03 0.09 0.21 0.02

AZ31B-H24 2.55 Bal. 0.79 0.041 0.002 0.31 0.008 - -

Mechanical properties
Tensile Strength Elongation (%) Modulus (MPa) Microhardness (Hv0.3)
(MPa)

AA7075-T6 581.95 20.01 70039.7955 184.4 (average)

AZ31B-H24 274.2 16.48 38266.045 67 (average)

Microstructure of the base metals (BM) is observed in Figure 1. AA7075-T6

alloy presents elongated grains and Mg2Zn precipitates by the T6 condition
(precipitation hardening [11]), Al2CuMg, Al7Cu2Fe and Mg2Si phases. AZ31B-
H24 alloy consists of equiaxed grains and some other deformed grains of different sizes,
with the presence of Al-Mn particles.

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 Figure 1. Base metals, (a) AA7075-T6 and (b) AZ31B-H24.

The plates of the different alloys were joined in butt configuration, using a
STIR PDS Intelligent Stir Welding MTS machine and utilizing the following range of
parameters: rotational speed (w) between 200 and 800 rpm, welding speed (v) from 30 to
60 mm/min and a tilt angle from 1° to 3°. In some cases, a tool offset of 1 mm was used
into Mg-based alloy and positioning the Mg on the advancing side. Cross-section of the
weld was prepared according to the standard metallographic procedure and etched with a
solution of 10 ml acetic acid, 10 ml distilled water and 4.2 g picric acid in 100 ml ethanol
as well as with Keller's to reveal the microstructure of Mg and Al, respectively. Macro-
and microstructural characterization were developed using a Nikon SMZ 7457
stereoscope, Nikon Eclipse MA optical microscope, scanning electron microscopy
(SEM) using a Philips XL30 microscope equipped with an energy dispersive (EDS)
detector. The stir zone was analyzed by X-ray diffraction (XRD) in a Rigaku DMAX-
2200 diffractometer using Cu Kα (λ = 0.154 nm) radiation. The diffraction patterns were
obtained in a range of 30° to 100° (2θ) with step of 0.02° s−1. Tensile tests were
performed according to ASTM E8 in MTS QTEST/100 universal machine (2 specimens
per weld) and the microhardness distribution was measured at the center of the weld (3
mm from the top of the weld) with a Vickers indenter with 0.3 kgf of load and 15 s of
dwelling time utilizing 2500 TUK microhardness tester.

Discussion

Weld appearance

Figure 2 shows the surface appearance of some dissimilar joints of Al/Mg by

the FSW process. It is observed that increasing rotational speed there is a high heat
generation during the welding, causing a greater plasticization of the materials but when
it is used an inadequate tool tilt angle, the tool shoulder can not keep the deformed
material inside the joint, expelling it out of the weld. Due to the above, in some joints
there is a lack of fill and excessive flashing defect. On the other hand, increasing the
welding speed, the heat generation is reduced, causing a less plasticization of the alloys
during the process, difficulting the joint between them and possibly favoring the crack
formation along the weld. Also, it is appreciated that a sound joint can not be obtained by
positioning the magnesium alloy on the advancing side and using a tool offset. But it can
be mentioned that the joint was obtained without the presence of the aforementioned
defects, this, by placing the Al on the advancing side and using w= 200 rpm, v= 30
mm/min, tilt angle of 1° without tool offset into Mg-based alloy (0 mm).
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 Figure 2. Defects of the welds, a) excessive flashing, b) crack, c) surface lack of fill and excessive flashing and d) Crack
and excessive flashing. (Advancing side: AS and Retreating side: RS)

Macro- and microstructure

Figure 3 shows the different cross-sectional areas of the dissimilar joint with
internal defects such as the tunnel, lack of penetration (Figure 3a) and cavities (Figure
3b). Tunnel and cavities defects can be attributed to an insufficient heat generation
during the welding due to the low rotational speed used, making plasticization of the
materials difficult. Moreover, the lack of penetration is due the pin being shorter than the
thickness of the plates resulting in inadequate penetration. Kah et al. [12] mention that an
incorrect pin length with respect to workpiece thickness and change in penetration depth
due to variation of the pieces thickness along the weld line can cause this defect type. In
Figure 3b it can be seen that the stir zone (SZ) presents complex flow patterns as
lamellar-like shear bands of Al and Mg alloy that repeat intermittently and have been
previously observed in other dissimilar joints of Al/Mg by FSW [13, 14]. This structure
is caused by the material which is incorporated by the thread of tool pin at each rotation,
further being produced by the severe deformation during the FSW and the different
deformability of Al and Mg [14]. Figure 3c shows the dispersion between the Mg and Al
in the SZ; furthermore, shows the presence of the IMC of Al-Mg observed in other
studies [9, 10, 13, 14]. In some investigations [8] it is mentioned that in welds of Al/Mg
by FSW process occurs a grain refinement in the SZ attributed to the severe plastic
deformation, caused by the tool pin and heat generation produced by the friction between
the material and the tool shoulder. In Figure 3d it is possible to observe a decrease of
approximately 70% in the grain size of the thermomechanically affected zone (TMAZ).

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 Figure 3. Micrographs of the cross-section of dissimilar AA7075-T6 to AZ31B-H24.

Scanning electron microscopy and x-ray diffraction studies

With respect to the results of SEM-EDS, its observed (Figure 4a) that the
darker the lamellar bands are, higher the Mg content is, this, in specific zones with the
presence of Zn. In the weld AA7075-T6/AZ31B-H24 there is the formation of Al3Mg2
intermetallic compound in the laminar structure according to the spectrums obtained
from the EDS analysis (Figure 4b) and to their chemical composition (Table II). Its
presence can be attributed to: (1) the formation of a constitutional liquation and (2)
existence of a higher Al content in the stir zone because no tool offset was used into Mg
alloy during the process. On the other hand, it was possible to observe some dispersed
phases in the SZ, such as Mg2Si (Figure 4c), Al2CuMg (Figure 4c), MgZn2 precipitates
(Figure 4d), Al7Cu2Fe (Figure 4d) and Al-Mn particles (Figure 4e) according to their
chemical composition shown in Table II.

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 Figure 4. SEM-EDS analysis of intercalated microstructure of lamellar-like shear bands (a) Mg content in lamellar, (b)
Al3Mg2 intermetallic compound and particles in SZ (c) Mg2Si and Al2CuMg, (d) MgZn2 and Al7Cu2Fe and (e) Al-Mn
particles.

Table II. Chemical composition (wt. %) obtained by EDS at the ubication shown in Figure 4.

Ubication Al Mg Zn Si Cu Mn Fe Cr Ca O Phase

5 62.35 31.07 6.58 - - - - - - Al3Mg2

6 65.73 25.97 8.3 - - - - - - Al3Mg2

7 62.58 4.71 2.7 21.95 - - - - - 8.06 Mg2Si

8 62.3 9.88 - - 27.82 - - - - - Al2CuMg

9 60.19 11.37 11.44 - 5.64 0.79 - 9.4 1.17 - MgZn2

10 66.91 5.66 - - 7.68 - 19.76 - - - Al7Cu2Fe

11 55.12 - - - - 44.88 - - - - Al-Mn

XRD technique was used in the stir zone to complement MEB-EDS analysis.
Figure 5 shows the diffractogram in which formation of the Mg-rich intermetallic
compound (Al12Mg17) in the weld is also observed. Therefore, the temperature during the
process may have exceeded both eutectic of Mg + Al 12Mg17 (437 °C) and the Al +
Al3Mg2 eutectic (450 °C), based on the binary phase diagram Al-Mg [15]. However, the
Zn presence can decrease the eutectic temperature of these intermetallics according to the
ternary phase diagram Al-Mg-Zn [15]. Also, Figure 5 shows the presence of other phases
that may be impurities like Fe-Zn compound because this phase is not found in base
metals and has not been observed in other studies on this type of joints [16]. However, a
more detailed analysis is necessary to confirm the above.
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 Figure 5. Spectrum obtained by XRD analysis of SZ.

Microhardness (hv)

Figure 6 shows an increase of microhardness (122 Hv) in agreement with the

other reported in the literature [7-14] and can be attributed to two factors: (1) grain
refinement, product of severe plastic deformation and (2) formation of IMC (Al3Mg2 and
Al12Mg17) in SZ [8]. It is appreciated a hardness decreases in the heat affected zone
(HAZ) and TMAZ with respect to the BM on the side of the Al alloy caused by the
coarsening, dissolution and reprecipitation of the strengthening particles by thermal cycle
[17], due to this property in Al hardenable alloys greatly depends on the strengthening
precipitates rather than the grain size. The decrease in hardness on the Mg side can be
attributed by the grain coarsening and annealing due to the temperature cycle during
welding.

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 Figure 6. Hardness profile of dissimilar joint AA7075-T6/AZ31B-H24.

Tensile properties

Table III shows the results obtained from the joint AA7075-T6/AZ31B-H24.
The dissimilar weld presents a lower tensile strength compared to the base metals. The
specimens fractured in the weld area during the test, which can be attributed to the
defects present in the joint (tunnel, cavities and lack of penetration). The strength of this
weld is due to the complex microstructure presented. Dissimilar joint present a brittle
behavior due to the formation of brittle and hard IMC in the weld.

Table III. Tensile properties of Al/Mg joint by FSW.

Tensile strength (MPa) Elongation (%) Modulus (MPa) Failure location

AA7075-T6/AZ31B-H24 (1) 56.8 0.195 30489.555 Welding

AA7075-T6/AZ31B-H24 (2) 65.9 0.125 69701.769 Welding

Average 61.35 0.160 50095.662 -

Conclusions

FSW joints of the AA7075-T6 and AZ31B-H24 alloys were performed with
different welding parameters and based on the results, it is possible to conclude:
Defects like excessive flashing, lack of fill and cracks are presented when it is used a
higher rotational and welding speed, as well as an inadequate tilt angle.
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 No sound welds are obtained positioning the magnesium alloy on the advancing side
or using the tool offset in this alloy (AZ31B-H24).
The best joining condition was obtained using w= 200 rpm, v= 30 mm/min, 1° of tilt
angle and placing the Al alloy on the advancing side.
Defects like tunnel, cavities and lack of penetration are present in the joint.
SZ shows an intercalated lamellar structure of Al and Mg material, as well as the
formation of IMC Al3Mg2 and Al12Mg17.
The obtained hardness (~122 HV) in the SZ was due to the refinement and presence of
IMC.
Under tensile stresses, the fracture occurred in the welding zone.
The tensile strength of the joint was 61.35 MPa, promoting a brittle behavior by the
presence of the compounds Al3Mg2 and Al12Mg17.

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