Accepted Manuscript

Microstructure and mechanical properties of dissimilar inertia friction welding of 7A04

aluminum alloy to AZ31 magnesium alloy

Wei Guo, Guoqiang You, Guangyu Yuan, Xiuli Zhang

PII: S0925-8388(16)33697-0
DOI: 10.1016/j.jallcom.2016.11.218
Reference: JALCOM 39715

To appear in: Journal of Alloys and Compounds

Received Date: 26 August 2016

Revised Date: 9 November 2016
Accepted Date: 16 November 2016

Please cite this article as: W. Guo, G. You, G. Yuan, X. Zhang, Microstructure and mechanical
properties of dissimilar inertia friction welding of 7A04 aluminum alloy to AZ31 magnesium alloy, Journal
of Alloys and Compounds (2016), doi: 10.1016/j.jallcom.2016.11.218.

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 ACCEPTED MANUSCRIPT

Microstructure and mechanical properties of dissimilar inertia

friction welding of 7A04 aluminum alloy to AZ31 magnesium alloy

Wei Guoa, Guoqiang Youab*, Guangyu Yuana, Xiuli Zhanga

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a
College of Materials Science and Engineering, Chongqing University, Chongqing

400045, China

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b
National Engineering Research Center for Magnesium Alloys, Chongqing University,

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Chongqing 400044, China

*
Corresponding author: Guoqiang You,

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Tel.: +86-023-65112626; E-mail address: ygq@cqu.edu.cn.

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ABSTRACT

The dissimilar joints between 7A04 aluminum alloy rod and AZ31 magnesium

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alloy rod were produced by inertia friction welding. The effects of friction pressure on

microstructure and mechanical properties of the joints were investigated. Results

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showed that intermetallic compounds (IMCs), mainly Al12Mg17 and Al3Mg2, were

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formed at the interfaces. A large amount of microcracks were generated in IMCs

interlayer. The thickness of IMCs layer decreased significantly with increasing

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friction pressure. The mechanical properties were assessed by tensile test and

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microhardness. The mechanical properties of joints largely lies on the characteristic of

IMCs interlayers at the interface. The tensile strength of the joints increases
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remarkably with increasing friction pressure. The maximum tensile strength of 96
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MPa was achieved under the friction pressure of 124 MPa. All the tensile specimens
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failed in quasi-cleavage fracture mode along the boundary between IMCs interlayer

and Al base metal.

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Keywords: inertia friction welding; aluminum alloy rod; magnesium alloy rod;
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microstructure; tensile strength; fracture morphology

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1. Introduction

Magnesium alloy is well-known as the lightest metal structural materials with the

appealing characteristics of superior specific strength and recyclability [1-3]. At the

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same time, aluminum alloy is one of the most widely used light metal structure

materials due to good formability, high specific strength [4-6]. In order to achieve a

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combination of individual properties, it is necessary to realize the sound joints

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between magnesium alloy and aluminum alloy. However, the welding of aluminum

alloy and magnesium alloy is considered to be a great challenge because of the

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formation of excessive brittle IMCs.

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A variety of fusion welding processes, including arc welding, laser welding, have

been adopted. Ben-Artzy, A et al. [7] used Gas Tungsten Arc (GTA) and Electron
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Beam (EB) welding techniques to study the weldability of Al-Mg. It was found that
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intermetallic phase (Mg17Al12) in the fused zone is the main reason causing brittleness
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and low strength of the joints. P Liu et al. [8] studied the microstructure and

performance of Mg-Al TIG welded joint. The results indicated that the weld metal
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was mainly composed of dendrite crystal and the brittleness phase. The fracture

morphology was a typical cleavage fractures with a river pattern on the Mg side.
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Borrisutthekul R et al. [9] carried out laser welding between AZ31B magnesium alloy
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and A5052 aluminum alloy. The intermetallic layer formed near interface significantly

degraded the joining strength. Therefore, conventional fusion welding is not feasible

for this couple in most cases.

Previous studies have demonstrated that joints with reasonable strength could be

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produced using solid-state welding techniques. B Fu et al. [10] obtained sound friction

stir welded joints between 6061 Al alloy and AZ31 Mg alloy. IMCs of Al12Mg17 and

Al3Mg2 formed and the eutectic structure existed in the nugget zone. Under

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optimizing welding parameters, the tensile strength of the joints could reach up to 175

MPa. Liu P et al. [11] reported that IMCs, such as MgAl, Mg3Al2 and Mg2Al3,

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appeared in the diffusion zone of Mg-Al diffusion bonded joint. Limin Zhao et al. [12]

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studied the Mg-Al joint by diffusion bonding with a Zn interlayer. The average shear

strength reached up to 70 MPa. I. Bhamji et al. [13] conducted linear friction welding

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of Al-Mg. IMCs (Al12Mg17 and Al3Mg2) volume fraction decreased with increasing

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welding pressures. Joints with reasonable strength could be produced. Katoh K et al.

[14] tested the mechanical properties of brake type friction welded joints between
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AZ31 Mg alloy and 1050 Al alloy. The weld was composed of compound layer and
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mechanical mixing layer. The maximum tensile strength of welded joints was about
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90 MPa, which was slightly higher than that of the 1050 Al alloy. Zhida Liang et al.

[15] analyzed the microstructural characterization and mechanical properties of

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dissimilar continuous drive friction welding of 1060 aluminum to AZ31B magnesium

alloy. IMCs (Al3Mg2 and Al12Mg17) and microcracks were generated in the interfaces.
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With increasing the friction and forge pressure, the thickness of the reaction layer
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decreased on average and the amount of microcracks decreased gradually. The

maximum tensile strength was 138 MPa.

Inertia friction welding is a unique method of joining materials achieved by

hot-heavy working process. Moreover, inertia friction welding process that possibly

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limit the formation of IMCs can be more suitable for joints of Al-Mg because of the

advantages such as lower heat input, short welding cycle and less welding parameters.

Similar or dissimilar materials, such as the GH4169 superalloy [16], 8009 aluminum

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[17], titanium alloy [18], K418-42CrMo [19], superalloy 720Li to IN718 [20],

copper-steel [21] and aluminum-steel [22], of inertia friction welding have been

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carried out successfully. However, previous studies have rarely used inertia friction

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welding technology to produce Al-Mg joints. Therefore, it has a great significance to

investigate the feasibility of joining Al alloy to Mg alloy by inertia friction welding.

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In this study, the dissimilar inertia friction welding of 7A04 Al alloy and AZ31

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Mg alloy was carried out. The friction pressure was selected as key variable. The

effect of friction pressure on microstructure and mechanical properties of welded

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joints was analyzed. Additionally, fracture morphology was discussed as well.
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2. Materials and methods

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Materials used in the investigations were commercial extruded AZ31 magnesium

alloy and extruded 7A04 aluminum alloy. As shown in Fig. 1, both of base materials
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were machined to rods of 30 mm in diameter and 80 mm in length. The chemical

compositions determined by X-ray fluorescence (XRF) and the tensile properties of

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base materials are showed in Table 1. Before welding, the connecting surfaces of the
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rods were polished by grit silicon carbide papers to eliminate the effect of oxide films

and surface roughness and then cleaned in acetone to remove dirt and grease.

Table 1

Chemical compositions (wt %) and tensile properties of base materials.

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0.2%
Tensile
Yield Elongation
Material Al Zn Si Mg Cu Mn Cr Fe strength
strength /%
/MPa

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/MPa

7A04 Bal. 6.73 3.74 2.41 1.94 0.5 0.22 0.22 510 446 114

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AZ31 3.44 1.14 0.07 Bal. / 0.07 / / 253 172 120

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The relation curves of parameters to time in the present welding experiments are

shown in Fig. 2. During the welding, one component was fixed on the rotary jaw, the

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other done on the stationary jaw. After the spindle being accelerated to a
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predetermined rotational speed, the motor cut off automatically. Then one component
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rotated at high revolutions with the spindle and the other moved axially under the

constant axial pressure. The connecting surfaces rubbed together and temperature
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close to the interfaces was increased until the materials reached plastic state. The
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rotational speed of the component with spindle slowed down gradually until the

welding procedure was finished.

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During the present inertia friction welding experiments carried out using a
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homemade machine, the Mg rods rotated with the spindle and the Al rods moved
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axially under the constant axial pressure. The experiments were performed four times

for each set of parameters at a constant rotational speed 4700 rpm, moment of inertia

0.5 Kg*m2. The axial pressure of 78, 93, 109, 124 MPa were selected for Test 1-4,

respectively.

After welding, the joints were cut perpendicular to the bonding interfaces to

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show cross-section. Joints autogenously fractured along the interface during

wire-electrode cutting process. Resin was used to mount the joint for microstructural

observation. Cross sections of welds were ground with 200-1200 grit silicon carbide

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papers and polished using 1 m alumina paste as final polish. Then the welds were

etched using Keller's reagent (4 ml HF+6 ml HCl+10ml HNO3+190 ml H2O) for 60 s

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on Al side and a mixture solution (5 m L acetic acid, 10 m L distilled water, and 5 g

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picric acid in 100 m L ethanol) for 20 s on Mg side, respectively. Scanning electron

microscope (SEM) and energy dispersive spectroscopy (EDS) were used to observe

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the microstructure of the welding zone. Vickers microhardness near the weld interface

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was measured by Vickers indenter under the load of 1 N dwelled for 15 s.

The specimens for the tensile test were prepared as rods of 28 mm in diameter.
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Tensile test was performed three times for every set of parameters to determine the
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tensile properties of the joints in accordance with GB/T 228.1-2010 standard using
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SANS XYB305C testing machine at a constant displacement rate of 1 mm/min at

room temperature. After the tensile test, the tensile fracture surfaces were analyzed
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with SEM and X Ray Diffraction (XRD).

3. Results and discussion

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3.1 Macrostructure characteristics at the interface zone

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Fig. 3 shows the macroscopic cross section of dissimilar inertia friction welded

joints at different friction pressures. The effects of friction pressure on deformation

and axial shortening of the welded joints are shown in Fig. 4. The plastic deformation

and axial shortening of the weld joints is quite different under different friction

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pressure. With increasing the friction pressure, edge curl was generated around the

joints, which implies that more plastic metal was extruded out from the connecting

interfaces. The single side flash bending towards Mg alloy side was uniformly formed

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around the joint circumference on Mg alloy side. On Al alloy side, however, obvious

plastic deformation only appears in Test 3 and 4. In comparison, the size of Al alloy

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flash is significantly smaller than that of Mg alloy. Moreover, the macroscopic cross

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section of the joints in Test 4 presents a slight concave interface projected into AZ31

Mg alloy. The asymmetrical deformation and concave interface are mainly due to the

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better mechanical properties at high temperature of Al alloy [23, 24].

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3.2 Microstructure at the interfaces zone

It is known that plastic deformation, mechanical interlocking, the diffusion of

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elements occur in inertia friction welding process. Under the effect of heat and
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pressure, the joint is formed with a metallurgical bonding interface. The SEM
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photographs and analysis results of chemical compositions in different region near

connecting interfaces are shown in Fig. 5. The distribution of Al and Mg element in

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the axial direction of the cross-section for Mg and Al sides was determined by EDS

line scan analysis. IMCs interlayer was observed clearly on the Mg alloy side
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although almost no IMCs interlayer was observed on the Al alloy side. On the Mg
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alloy side, the elements distribution of Mg and Al has a small plateau part within

several m close to the interfaces, implying that the formation of thin IMCs layers at

the interface. In contrast, only Al was detected on the Al alloy side, which reconfirms

that little IMCs interlayer appears on the Al alloy side. According to Mg-Al binary

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phase diagram as shown in Fig. 6, intermetallic phases (-Al12Mg17, -Al3Mg2) are

often produced. The formation of IMCs layers at the interface is caused by the solid

diffusion of elements. In theory, the larger diffusion coefficient of Mg atoms makes it

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easier for Mg to diffusion near the interface. In addition, the heavy plastic

deformation on Mg side enhances the diffusion of Mg atoms to some degree [25].

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However, the IMCs layers are formed on Mg side, which is in contradiction with that

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of Fe-Ti friction welded joints [26]. On the basis of the analysis of Mg-Al binary

phase diagram, the reason concerning the contradiction mainly contains two possible

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aspects. Firstly, the maximum solid solubility of Al elements in Mg (about 11.6 at. %)

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is lower than that of Mg in Al (about 18.6 at. %). The intermetallic compounds

precipitations are more likely to form in supersaturated solid solution on Mg side.

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Besides, -Al12Mg17 is formed with a wider range of phase composition.
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Consequently, a large amount of -Al12Mg17 (58.6 at. % Mg) tend to form near the Mg
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side, and -Al3Mg2 (60 at. % Al) is likely to appear near the Al side. The Gibbs free

energy of Al12Mg17 and Al3Mg2 were compared [27]. The date reveals that the free
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energy of Al12Mg17 is far lower than that of Al3Mg2 at the temperature ranging from

225 K to 1000 K. The results indicate that Al12Mg17 is more stable than Al3Mg2. Thus
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Al12Mg17 is more probable to form at the interface in aspect of Gibbs free energy.
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The thickness of IMCs interlayer at the axial direction of the joint decreased

significantly with increasing friction pressure. Heavier deformation and shorter

welding time are the major factors on the thinner IMCs interlayer. On one hand,

heavier deformation leaded to more IMCs extrusion under higher friction pressure. On

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the other hand, the welding time inversely related to friction pressure, as a result of

the certain rotational speed in the experiment. The shorter welding time contributed to

less formation of IMCs at welding interfaces. In addition, the thickness of reaction

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layer is different depending on the different location. An enormous amount of IMCs

appeared in the half radius zone and the periphery zone, but much less IMCs appeared

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in the central zone. The inhomogeneous distribution of reaction layer was mainly

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caused by the inhomogeneous distribution of friction stress and temperature. The

thermoplastic metal was expelled from internal to external at the weld interfaces.

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More heat generated and more accumulation leaded to more existence of IMCs in

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peripheral region, although the heavier plastic deformation occurred. However, the

intermetallic phases generated in the center zone was more likely to be transferred out
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to peripheral region because of the concave interface of joint. But the maximum
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thickness is about 10 m, which is much thinner than that in continuous drive friction
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welded joints [15].

Table 2
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The EDS results of different position at the joint interface (at. %).
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Position Mg Al C O Possible phase

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1 63.32 36.68 - - Al12Mg17

2 56.20 43.80 - - Al12Mg17

3 2.62 47.26 25.59 24.53 Impurity

4 42.23 57.77 - - Al3Mg2

5 2.35 97.65 - - Al

6 3.02 45.08 30.59 21.30 Impurity

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Fig. 7 shows the microstructure characterization at high magnification in location

a-d of Fig. 5. Table 2 lists the chemical compositions and analysis results of the

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positions 1-6 in Fig. 7. As shown in Fig. 7(a) and (c), a large amount of microcracks

were generated in IMCs interlayer on Mg side. The distribution of IMCs presents

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different morphologies including dispersive particles and laminar pattern. Combining

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chemical compositions of the specified positions and the Mg-Al binary phase diagram,

the intermetallic phases is inferred as Al12Mg17 and Al3Mg2. EDS results of position 3

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and 6 demonstrate the existence of particles impurity on Al side. The main cause for

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microcracks is a large amount of brittle IMCs, especially laminar pattern compounds

(Fig. 7a). Additionally, high stress concentration contributes to the formation of

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microcracks as well. Different thermodynamic properties of the base metals, high
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heating speed, cooling speed and heavy plastic deformation play important roles in
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stress concentration.

3.3 Mechanical property of the joints

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3.3.1 Vickers microhardness

Fig. 8 shows the microhardness distribution in the welding zone of the inertia
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friction welded joints. The vickers microhardness values of Al alloy substrate is much
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higher than that of Mg alloy substrate. It can clearly be seen that the vickers

microhardness of Mg alloy substrates adjacent to the interface was higher than that of

base metal. Owing to heat input and heavier plastic deformation, the grain refinement

occurred adjacent to the joints interface. According to Hall-Petch relationship, the

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higher hardness value of Mg alloy substrate resulted from grain refinement. Moreover,

the microhardness along periphery is slightly higher than that along central line as a

result of more heat input and heavier plastic deformation in outer zone. However, the

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contrary situation occurred on the Al alloy side. The Al alloy base metal used in this

experiment was extruded 7A04 Al alloy, which was already work hardened before the

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welding procedure. Under the friction heat input and slight plastic deformation,

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thermal softening occurred on Al alloy side. But, the microhardness of a narrow

region adjacent to the interface is slightly higher than Al alloy base metal in test 4,

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which means that grain refinement occurred under adequately plastic deformation.

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Previous studies showed that the microhardness was much higher in the zone within

0.2 mm close to the welding interfaces than that in other zones [15]. By contrast, the
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brittle IMCs layer is thinner than 10 m in Fig. 5. Therefore, the much higher peak
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failed to be revealed in the results. In Fig. 8, the results reconfirm that the brittle IMCs
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layer in the joints above is distinctly thinner than that in continuous drive friction

welded joints.
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3.3.2. Tensile strength

Fig. 9 presents the tensile strength of the joints as a function of friction pressure.
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The results of tensile test indicate that the friction pressure has significant effects on
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the tensile strength of dissimilar inertia friction welding Al-Mg joints. With increasing

friction pressure, the tensile strength of the welding joints increases remarkably. The

maximum tensile strength, 96 MPa, was achieved under friction pressure of 124 MPa.

It is generally considered that the tensile strength of dissimilar joints greatly lies

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on the microstructure at the interfaces [26]. The characteristic of IMCs layers is a

sensitive factors of mechanical properties. With increasing friction pressure, the

thickness of IMC interlayer decreased significantly and the tensile strength of the

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joints increases remarkably. The increased tensile strength is related to the shorter

welding time and heavier plastic deformation occurred as a result of the increased

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friction pressure. On one hand, the shorter welding time decreased the formation of

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brittle phases at the joint interfaces. On the other hand, the heavier plastic deformation

removed the oxide films on the connecting surfaces more adequately and leaded to

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more brittle phase extrusion. Besides, the higher friction pressure contributed to

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mechanical interlocking and the diffusion of elements, which was benefit for

metallurgical bonding. The greater temperature gradient due to higher friction

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pressure resulted in narrower heat affected zone, too. Previous studies demonstrated
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that the forge pressure would improve the weld interface adherence and joint
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efficiency [13, 15], which is equally applicable to this experiment.

Although the thickness of IMC interlayer is restricted effectively, all the friction
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welded samples fail at the interfaces during tensile test. The microcracks generated at

the interface should be partly responsible for the joint strength. The microcracks are
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formed due to existence of brittle IMCs and higher stress concentration. In tensile
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tests, the presence of the microcracks leads to an uneven distribution of stresses and

acts as crack initiation. Under tensile stresses, crack prefers to grow along microcracks.

Additionally, relatively low center velocity may lead to insufficient heat generation in

center zone. As a result, weak mechanical interlocking produce, which is also

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unfavorable for good metallurgic bonding.

3.4. Analysis of fracture surfaces

3.4.1. Phases analysis by XRD on both fracture surfaces

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The phase compositions at the fracture surfaces of tensile samples in Test 4 were

analyzed by XRD as shown in Fig. 10. The results show that the fracture surface of Al

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side contains Al, Al3Mg2 and Al12Mg17 diffraction peak. The main peaks only

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corresponding to Al emerge on Al side. But the main peaks corresponding to Mg and

Al12Mg17 emerge on Mg side, which reconfirms the result that the IMCs are mainly

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formed on Mg side. Besides, the intermetallic phase Al12Mg17 was detected on both of

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the fracture surfaces, which would degrade mechanical properties of joints.

3.4.2. Macroscopic fracture surfaces

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Fig. 11 shows macroscopic fractography of tensile specimens for varied friction
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pressure. All the specimens failed at the welding interfaces during tensile test without
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obvious plastic deformation. The fracture surfaces are rather smooth and consist of

some continuous and shining plane, which confirms that the failure is typical brittle
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fracture. Besides, it is clear that the fracture surfaces are relatively rough at low

friction pressure. Due to the effects of friction heat and torque, the fracture surfaces
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present spiral lines of deformation distinctly. But the distribution of spiral line is
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inhomogeneous. The features of center zone is clearly distinguished from other

regions, which may indicate that lighter plastic deformation and insufficient heat

generate in center zone.

3.4.3. Microscopic morphology and chemical compositions analysis of fracture

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In order to understand the failure mechanism, SEM and EDS spot scanning were

carried out to observe the fracture surfaces of tensile specimens. Fig. 12 shows the

SEM fractography and EDS spot scanning results acquired from different zone on

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each side of tensile failure samples in Test 1. In Fig. 12 (a) and (d), cleavage steps and

defects, such as several voids and some cracks, appear in the center zone. The

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chemical compositions in the position 3 of crack initiation indicated that the cracks

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may occur in the Mg matrix metal. In Fig. 12 (b) and (e), microvoids and tear ridges

appear in the middle zone. Based on the EDS results in position 4 consisted of

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61.78% Mg-38.22% Al, the cracks may originate from Al12Mg17. Fig. 12(c) shows

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river pattern, tear ridges. In Fig. 12(f), the chemical compositions in position 5

indicated that the radial marks may be caused by intermetallic phase Al3Mg2. The
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analysis of fractographs indicates that the fracture of the joint in Test 1 is
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quasi-cleavage fractures with cleavage steps, tear ridges, river pattern, microvoids.
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Fig. 13 shows the SEM fractography and EDS spot scanning results of the joint

in Test 2. In Fig. 13 (a) and (d)), some cracks appear in the center zone. EDS results of
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position 1 shows that cracks was presumably caused by Al3Mg2 and precipitates

Si2Mg. The chemical compositions in the position 4 of crack initiation indicated that
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the cracks may be primarily caused by Al12Mg17. In Fig. 13 (b) and (e), cleavage steps
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and tear ridges appear in the middle zone. In Fig. 13 (c), river pattern, tear ridges were

generated in the Al matrix metal according to the EDS analysis results of position 3.

In Fig. 13(f), the chemical compositions in position 6 indicated that the crack initiator

of fan pattern may be also caused by intermetallic phase. The analysis of fractography

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indicates that the fracture of the joint in Test 2 is quasi-cleavage fractures with

cleavage steps, tear ridges, river pattern, fan pattern and microvoids.

Fig. 14 shows the SEM fractography and EDS spot scanning results acquired

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from different zone on each side of tensile failure samples in Test 3. In Fig. 14 (a) and

(d), cleavage steps and microcracks are visible clearly in the center zone. In Fig. 14 (b),

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fan pattern, steps and few microcracks appear in the middle zone of fracture surface.

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According to the EDS analysis results of position 5 consisted of 65.40% Mg-34.60%

Al, crack initiation site of fan pattern is caused by Al12Mg17. In Fig. 14(f), the

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chemical compositions in position 3 indicate that the cracks may be caused by phases

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Al3Mg2. The analysis of fractographs indicates that the fracture of the joint in Test 3 is

quasi-cleavage fractures with cleavage steps, fan pattern, tear ridges and microvoids.
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Fig. 15 shows the SEM fractography and EDS spot scanning results acquired
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from different zone on each side of tensile failure samples in Test 4. Fig. 15(a)
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exhibits tear ridges, equal-axis dimples and microvoids, which indicated that the

fracture mode is mixed fracture of brittle fracture and ductility fracture. In Fig. 15(d),
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cleavage steps and microcracks are visible clearly in the center zone. In Fig. 15(b) and

(c), the atomic ratio of Mg to Al on Al alloy side changes dramatically. The content of
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Mg elements is higher than that of Al, which indicates that cracks occurred in the Mg
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matrix metal owing to the thinner IMCs interlayer. In Fig. 15(f), the chemical

compositions in position 6 are consisted of 60.12%Mg-39.88%Al, which indicates

that the crack initiator of fan pattern was caused by intermetallic phase Al12Mg17. The

analysis of fractography indicates that the fracture of the joint in Test 4 is

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quasi-cleavage fractures with cleavage steps, fan pattern, tear ridges and microvoids.

According to the observation and chemical compositions analysis of fracture

surface for joints in different friction pressure, it can be concluded that all the joints

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failed in quasi-cleavage fracture mode dominated by numerous of cleavage steps, fan

pattern, tear ridges, microcracks and a small amount of microvoids. With increasing

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friction pressure, more microvoids and tear ridges appear in fracture surface, which

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reconfirms mechanical properties of welding joints increases gradually. In addition,

fracture characteristics are different significantly depending on different location.

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Large numbers of microcracks and cleavage steps tend to generate in the center zone.

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In the middle zone and periphery zone, fracture surfaces show predominant delicate

cleavage steps, tear ridges, cleavage river pattern with a small quantity of dimples and
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microvoids. Based on the above analysis of EDS spot scanning results, it can be
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concluded that the origination and propagation of cracks in tensile joints is closely
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related to brittle IMCs. According to the analysis of atomic ratio of Mg to Al on the

crack initiators, cracks are easily generated near intermetallic phase Al12Mg17. In test
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4, the percentage of Mg elements is higher than that of Al, which indicates that cracks

initiators tended to transfer from intermetallic phase to Mg matrix metal. It can be

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concluded that Al12Mg17 and Al3Mg2 degrade mechanical properties of joints. The
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fracture occurred at the boundary between IMCs and Al substrate, which is consistent

with discussion about interfacial microstructure of the joints.

4. Conclusions

1. The effects of friction pressure on dissimilar inertia friction welding of Al-Mg have

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been investigated. IMCs, consisting of Al12Mg17 and Al3Mg2, were generated at the

interface, including a large number of microcracks. With increasing friction

pressure the thickness of IMCs layer decreased significantly. But the thickness of

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IMCs is about several m.

2. The microhardness of Mg alloy substrates adjacent to the interface is higher than

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that of base material due to grain refinement, while that of Al alloy substrates

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declines under the welding conditions. This indicates that thermal softening

occurred on Al alloy side.

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3. With increasing the friction pressure, the tensile strength of the weld increases

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remarkably. The maximum average tensile strength of 96 MPa was achieved

under the friction pressure of 124 MPa. All the tensile specimens failed in
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quasi-cleavage fracture mode along the interface between IMCs layer and Al base
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metal.
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Acknowledgments

The authors would like to thank financial support from Large-scale

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Instrumentation Equipment Open-end Foundation of Chongqing University (Grant no.

201512150010). They also wish to thank for Mr Xiaoling Xu for his devoted
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contribution to this research project.

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[2] MORDIKE B. L, EBERT T. Magnesium: Properties applications potential [J].

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[3] Easton M, Beer A, Barnett M, et al. Magnesium alloy applications in automotive

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Figure captions

Fig. 1. Shapes and dimensions of specimens used for inertia friction welding.

Fig. 2. The curves of parameters to time in the present inertia friction welding

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experiments.

Fig. 3. The macroscopic cross section of the joints at different friction pressures.

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Fig. 4. Effects of friction pressure on the burn-off.

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Fig. 5. Line scan analysis across the interfaces around the central zone, the half radius

zone, the periphery zone of the joint in Test 1-4, respectively.

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Fig. 6 Mg-Al binary phase diagram.

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Fig. 7. The magnification images in location ad of Figs. 5.

Fig. 8. Microhardness distribution of inertia friction welded joints along periphery,

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middle and central line, respectively.
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Fig. 9. Tensile strength of inertia friction welded joints.

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Fig. 10. X-ray diffraction analysis results of the fracture surfaces of the joint in Test 4.

Fig.11. Macroscopic fractography of tensile fracture surfaces of inertia friction

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welded joints.

Fig. 12. The SEM fractography and EDS results (at. %) of the joint in Test 1.
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Fig. 13. The SEM fractography and EDS results (at. %) of the joint in Test 2.
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Fig. 14. The SEM fractography and EDS results (at. %) of the joint in Test 3.

Fig. 15. The SEM fractography and EDS results (at. %) of the joint in Test 4.
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Highlights
1. Previous studies have never used inertia friction welding technology to produce
Al-Mg joints.
2. The thickness of intermetallic compounds interlays consisted of Mg17Al12 and

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Al3Mg2 is only several m.
3. The tensile strength of joints largely lies on the characteristic of intermetallic
compounds interlayers at the interface.

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4. With increasing friction pressure the tensile strength of the joints increased

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remarkably.
5. The maximum tensile strength of the joints can reach up to 96 MPa.

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