Numerical Prediction of Intermetallic Compounds Thickness in Friction Stir Welding of Dissimilar Aluminum/Magnesium Alloys

doi:10.1007/s40195-021-01238-w

Abstract

Abstract:

An atomic diffusion model is developed to predict the thickness of intermetallic compounds (IMCs) at the interface of aluminum/magnesium alloys in dissimilar friction stir welding. Both the temperature and the strain rate associated with dislocation density at the checking point are used to determine the diffusion coefficients. The variations of the diffusion coefficients and the thickness of IMCs are quantitatively analyzed at selected characteristic time instants during welding process. It is found that the dislocation density can increase the diffusion coefficient and plays a dominant role in the IMCs formation during the plastic deformation stage. Especially in magnesium alloy and Al₁₂Mg₁₇, the diffusion coefficient is increased by two orders of magnitude or even nearly three orders of magnitude by considering the dislocation density. The temperature is the main influencing factor after the end of plastic deformation. The model is validated by comparing the predicted thickness of IMCs with the experimentally measured results.

Key words: Friction stir welding, Aluminum alloys, Magnesium alloy, Intermetallic compounds, Atomic diffusion, Strain rate

Chunliang Yang, Chuansong Wu, Junjie Zhao. Numerical Prediction of Intermetallic Compounds Thickness in Friction Stir Welding of Dissimilar Aluminum/Magnesium Alloys[J]. Acta Metallurgica Sinica (English Letters), 2021, 34(10): 1375-1385.

Figures/Tables 14

References 31

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Temperature (K)	Width of Al₃Mg₂ (μm)		Width of Al₁₂Mg₁₇ (μm)
Temperature (K)	Measured [29]	Calculated	Measured [29]	Calculated
693	198	200	108	118
673	181	166	69	88
653	147	140	40	64

Temperature (K)	Width of Al₃Mg₂ (μm)		Width of Al₁₂Mg₁₇ (μm)
Temperature (K)	Measured [29]	Calculated	Measured [29]	Calculated
693	198	200	108	118
673	181	166	69	88
653	147	140	40	64

Time instant	D (m²/s), D_T (m²/s)	c_Al = 0.03 (Mg)	c_Al = 0.4 (Al₁₂Mg₁₇)	c_Al = 0.6 (Al₃Mg₂)	c_Al = 0.97 (Al)
Beginning of deformation, instant (a)	D	2.99 × 10^-18			1.33 × 10^-15
	D_T	2.81 × 10^-18			1.33 × 10^-15
	D /D_T	1.06			1
Beginning of IMCs generation, instant (b)	D	1.698 × 10^-15			1.51 × 10^-15
	D_T	3.43 × 10^-18			1.46 × 10^-15
	D /D_T	495			1.03
Peak of dislocation density	D	1.62 × 10^-13	6.18 × 10^-13	1.79 × 10^-12	5.28 × 10^-15
	D_T	3.35 × 10^-17	1.54 × 10^-15	1.75 × 10^-12	4.33 × 10^-15
	D /D_T	4836	401	1.0229	1.22
Peak of strain rate, instant (c)	D	2.48 × 10^-13	8.94 × 10^-13	1.98 × 10^-12	7.23 × 10^-15
	D_T	6.85 × 10^-17	2.91 × 10^-15	1.94 × 10^-12	6.09 × 10^-15
	D /D_T	3620	307	1.0206	1.19
Peak of temperature, instant (d)	D	4.26 × 10^-13	1.36 × 10^-12	2.64 × 10^-12	1.40 × 10^-14
	D_T	3.29 × 10^-16	1.17 × 10^-14	2.63 × 10^-12	1.29 × 10^-14
	D /D_T	1295	116	1.0038	1.09
End of deformation, instant (e)	D	1.02 × 10^-13	3.51 × 10^-13	2.11 × 10^-12	7.01 × 10^-15
	D_T	8.10 × 10^-17	3.37 × 10^-15	2.107 × 10^-12	6.598 × 10^-15
	D /D_T	1259	104	1.0014	1.06
No longer increase of IMCs thickness, instant (f)	D	9.71 × 10^-15	4.11 × 10^-14	1.142 × 10^-12	1.16 × 10^-15
	D_T	1.62 × 10^-18	1.05 × 10^-16	1.14 × 10^-12	1.02 × 10^-15
	D /D_T	5994	391	1.0018	1.14

Time instant	D (m²/s), D_T (m²/s)	c_Al = 0.03 (Mg)	c_Al = 0.4 (Al₁₂Mg₁₇)	c_Al = 0.6 (Al₃Mg₂)	c_Al = 0.97 (Al)
Beginning of deformation, instant (a)	D	2.99 × 10^-18			1.33 × 10^-15
	D_T	2.81 × 10^-18			1.33 × 10^-15
	D /D_T	1.06			1
Beginning of IMCs generation, instant (b)	D	1.698 × 10^-15			1.51 × 10^-15
	D_T	3.43 × 10^-18			1.46 × 10^-15
	D /D_T	495			1.03
Peak of dislocation density	D	1.62 × 10^-13	6.18 × 10^-13	1.79 × 10^-12	5.28 × 10^-15
	D_T	3.35 × 10^-17	1.54 × 10^-15	1.75 × 10^-12	4.33 × 10^-15
	D /D_T	4836	401	1.0229	1.22
Peak of strain rate, instant (c)	D	2.48 × 10^-13	8.94 × 10^-13	1.98 × 10^-12	7.23 × 10^-15
	D_T	6.85 × 10^-17	2.91 × 10^-15	1.94 × 10^-12	6.09 × 10^-15
	D /D_T	3620	307	1.0206	1.19
Peak of temperature, instant (d)	D	4.26 × 10^-13	1.36 × 10^-12	2.64 × 10^-12	1.40 × 10^-14
	D_T	3.29 × 10^-16	1.17 × 10^-14	2.63 × 10^-12	1.29 × 10^-14
	D /D_T	1295	116	1.0038	1.09
End of deformation, instant (e)	D	1.02 × 10^-13	3.51 × 10^-13	2.11 × 10^-12	7.01 × 10^-15
	D_T	8.10 × 10^-17	3.37 × 10^-15	2.107 × 10^-12	6.598 × 10^-15
	D /D_T	1259	104	1.0014	1.06
No longer increase of IMCs thickness, instant (f)	D	9.71 × 10^-15	4.11 × 10^-14	1.142 × 10^-12	1.16 × 10^-15
	D_T	1.62 × 10^-18	1.05 × 10^-16	1.14 × 10^-12	1.02 × 10^-15
	D /D_T	5994	391	1.0018	1.14

Time instant (s)	Welding speed (mm/min)
	30	50	80
(a) Beginning of deformation	13.70	8.60	5.10
(b) Beginning of IMCs generation	13.78	8.67	5.15
(c) Peak of strain rate	16.86	9.77	6.60
(d) Peak of temperature	17.19	10.38	6.96
(e) End of deformation	18.20	11.85	7.30
(f) No longer increase of IMCs thickness	22.52	15.60	7.41