Welding and Joining of Magnesium Alloys (Woodhead Publishing in Materials)

409 Pages·2010·22.06 MB·English

by  Liu Liming

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Welding and joining of magnesium alloys
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© Woodhead Publishing Limited, 2010
1 Related titles:
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3 Failure mechanisms of advanced welding processes
4 (ISBN 978-1-84569-536-1)
5 Many new, or relatively new, welding processes such as friction stir welding, resistance
spot welding and laser welding are being increasingly adopted by companies to replace
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or improve on traditional welding techniques. Improvements in welding speed and
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ease of automation are often used as reasons for choosing advanced welding processes.
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Before advanced techniques are employed, their potential failure mechanisms should
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be well understood and their suitability for welding particular metals and alloys in
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different situations should be assessed. This important book will provide a critical
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analysis of advanced welding techniques and their potential failure mechanisms.
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3 Materials, design and manufacturing for lightweight vehicles
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5 Research programs into the manufacture of lightweight automobiles have led to the
6 consideration of a variety of materials, such as high strength steels, aluminium alloys,
7 magnesium alloys, plastics and composites. This research is driven by a need to reduce
fuel consumption to preserve dwindling hydrocarbon resources without compromising
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other attributes such as safety, performance, recyclability and cost. This important
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book will make it easier for engineers to not only learn about the materials being
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considered for lightweight automobiles, but also to compare their characteristics and
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properties. It also covers issues such as crashworthiness and recycling.
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The welding of aluminium and its alloys
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5 The welding of aluminium and its alloys is a practical user’s guide to all aspects
6 of welding aluminium and aluminium alloys, giving a basic understanding of the
7 metallurgical principles involved. The book is intended to provide engineers with
8 perhaps little prior acquaintance with the welding processes involved, a concise and
effective reference to the subject. It covers weldability of aluminium alloys, process
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descriptions, advantages, limitations, proposed weld parameters, health and safety
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issues, preparation for welding, quality assurance and quality control issues. It is
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essential reading for welding engineers, production engineers, production managers,
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designers and supervisors involved in the aluminium fabrication industry.
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© Woodhead Publishing Limited, 2010
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Welding and joining
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of magnesium alloys 6
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Edited by
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Liming Liu 3
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© Woodhead Publishing Limited, 2010
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2 First published 2010, Woodhead Publishing Limited
© Woodhead Publishing Limited, 2010
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© Woodhead Publishing Limited, 2010
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Contents
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Contributor contact details xi 33
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Part I General 1
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1 Introduction to the welding and joining of magnesium 3
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L. Liu, Dalian University of Technology, China
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1.1 Background 3
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1.2 Characteristics of magnesium alloy welded joints
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under dynamic load 4
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1.3 Efficient gas metal arc welding of magnesium alloys 5
1.4 Dissimilar welding of magnesium alloys to other metals 6 33
1.5 References 7 44
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2 Welding metallurgy of magnesium alloys 9 66
L. Liu, Dalian University of Technology, China 77
2.1 Introduction 9 88
2.2 Weldability of magnesium alloys 10 99
2.3 Weldability of magnesium alloys to other metals 12 3300
2.4 References 14 11
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3 Preparation for welding of magnesium alloys 16 33
L. Liu, Dalian University of Technology, China 44
3.1 Introduction 16 55
3.2 Surface treatment of magnesium alloys 16 66
3.3 Welding groove for magnesium alloys 18 77
3.4 Preheating and postweld treatments for magnesium alloys 20 88
3.5 References 22 99
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vi Contents
1 4 Welding materials for magnesium alloys 23
2 L. Liu, Dalian University of Technology, China
3 4.1 Introduction 23
4 4.2 Hot extrusion process of welding materials 27
5 4.3 Component design of welding materials 32
6 4.4 Hot pull process of welding materials 34
7 4.5 Microstructure and strength of welding materials 35
8 4.6 References 36
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10 5 Welding and joining of magnesium alloys to
1 aluminum alloys 38
2 L. Liu, Dalian University of Technology, China
3 5.1 Introduction 38
4 5.2 Hybrid laser-tungsten inert gas welding of magnesium
5 and aluminum 39
6 5.3 Diffusion bonding magnesium to aluminum technology 44
7 5.4 Laser weld bonding magnesium to aluminum technology 49
8 5.5 Conclusion and future trends 60
9 5.6 References 61
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1 6 The joining of magnesium alloy to steel 63
2 L. Liu, Dalian University of Technology, China
3 6.1 Introduction 63
4 6.2 Existing problems in the joining of magnesium alloys to steel 64
5 6.3 Welding principles for the joining of magnesium alloys to steel 66
6 6.4 Direct joining of magnesium alloys to mild steel 69
7 6.5 Nickel-added joining of magnesium alloys to steel 74
6.6 Conclusion and future trends 77
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6.7 References 77
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1 7 Corrosion and protection of magnesium alloy welds 79
2 L. Liu, Dalian University of Technology, China
3 7.1 Introduction 79
4 7.2 Corrosion characteristics of magnesium alloy weldment 80
5 7.3 Improvement in the corrosion resistance of magnesium
6 alloy weldment 86
7.4 Conclusion and future trends 92
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7.5 References 93
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Contents vii
Part II Particular welding and joining techniques 95 1
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8 Brazing and soldering of magnesium alloys 97 3
T. WaTanabe, Niigata University, Japan 4
8.1 Surface preparation of magnesium alloys before joining 97 5
8.2 Brazing of magnesium alloys using flux and filler metal 103 6
8.3 Ultrasonic brazing of magnesium alloys with no flux 112 7
8.4 Soldering of magnesium alloys 117 8
8.5 References 120 9
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9 Mechanical joining of magnesium alloys 122
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M. Heger, böllhoff, Germany and M. HorsTMann, 2
Hella KGaA Hueck & Co., Germany
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9.1 Introduction 122
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9.2 Technologies with pre-punching operation and one-sided
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accessibility 123
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9.3 Technologies with pre-punching operation and two-sided
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accessibility 130
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9.4 Technologies without pre-punching operation and one-sided
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accessibility 133
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9.5 Technologies without pre-punching operation and two-sided
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accessibility 138
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9.6 Linear technology: hemming 145
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9.7 References 147
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10 Adhesive bonding of magnesium alloys 149
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L. Liu, Dalian University of Technology, China
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10.1 Introduction 149
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10.2 Surface treatments of magnesium alloys 149
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10.3 Adhesive for the bonding of magnesium alloys 154
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10.4 Cure for the bonding of magnesium alloys 154
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10.5 Applications of the bonding of magnesium alloys 154
10.6 Future trends 158 2
10.7 References 158 3
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11 Gas-tungsten arc welding of magnesium alloys 160
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L. Liu, Dalian University of Technology, China
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11.1 Introduction 160
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11.2 Gas-tungsten arc welding of magnesium alloys
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without filling wire 161
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11.3 Gas-tungsten arc filler welding of magnesium alloys 168
11.4 References 175 1
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viii Contents
1 12 Metal inert gas welding of magnesium alloys 178
2 g. song, Dalian University of Technology, China
3 12.1 Introduction 178
4 12.2 Pulsed metal inert gas welding for magnesium alloys 179
5 12.3 Alternating current metal inert gas welding for magnesium
6 alloys 185
7 12.4 Conclusion and future trends 194
8 12.5 References 194
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10 13 Variable polarity plasma arc welding of magnesium alloys 197
1 Z.D. ZHang, Dalian University of Technology, China
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13.1 Introduction 197
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13.2 Variable polarity plasma arc welding of magnesium alloys 199
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13.3 Variable polarity plasma arc weld bonding of magnesium
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6 13.4 Conclusion and future trends 226
7 13.5 References 227
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14 Hybrid laser-arc welding of magnesium alloys 229
20 g. song, Dalian University of Technology, China
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14.1 Introduction 229
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14.2 Low-power laser/arc hybrid welding of magnesium 230
3 14.3 Hybrid welding process with filler metal 244
4 14.4 Practical application 250
5 14.5 Conclusion and future trends 251
6 14.6 References 251
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8 15 Activating flux tungsten inert gas welding of
9 magnesium alloys 253
30 Z.D. ZHang, Dalian University of Technology, China
1 15.1 Introduction 253
2 15.2 Welding mechanism 254
3 15.3 Welding parameters 258
4 15.4 Microstructure of welding joints 267
5 15.5 Mechanical properties 271
6 15.6 Future trends 272
7 15.7 References 272
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9 16 Friction stir welding of magnesium alloys 274
40 H. ZHang, University of Science and Technology, Beijing, China
1 16.1 Introduction 274
2 16.2 Welding parameters and procedures 276
43X 16.3 Welding tools and equipment 280
© Woodhead Publishing Limited, 2010
Contents ix
16.4 Materials that have been or are being friction stir welded 282 1
16.5 Typical microstructures of friction stir welded magnesium 2
alloys 282 3
16.6 Properties of friction stir welded magnesium alloys 289 4
16.7 Weld defects of friction stir welded magnesium alloys 295 5
16.8 Applications of friction stir welded magnesium alloys 300 6
16.9 Future trends and sources of further information and advice 301 7
16.10 Acknowledgements 301
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16.11 References 301
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17 Laser welding of magnesium alloys 306
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J. sHan, Tsinghua University, China 2
17.1 Introduction 306 3
17.2 Character of the laser welding process and influence
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of laser welding parameters 307
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17.3 Laser welding of magnesium alloys 318
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17.4 Microstructure and properties of laser welding of magnesium
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alloys 322
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17.5 Typical defects of laser welding of magnesium alloys 332
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17.6 Outlook and future trends 346
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17.7 References 347
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18 Resistance spot welding of magnesium alloys 351
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L. Liu, University of Waterloo, Canada, J. Feng, Harbin Institute
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of Technology, China and Y. ZHou, University of Waterloo, Canada
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18.1 Introduction 351
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18.2 Fundamentals of resistance spot welding 351
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18.3 Welding conditions: surface 354
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18.4 Welding conditions: welding parameters 358
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18.5 Nugget growth and microstructure 359
18.6 Welding of magnesium alloys to other alloys 362 30
18.7 Equipment for the welding of magnesium alloys 363 1
18.8 Future trends 364 2
18.9 References 365 3
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aluminium sheets 367 6
s. Kore, Indian Institute of Technology, Guwahati, India and J. iMberT, 7
Y. ZHou and M. WorsWicK, University of Waterloo, Canada 8
19.1 Introduction 367 9
19.2 Fundamental theory of electromagnetic welding 368 40
19.3 Equipment for electromagnetic welding 369 1
19.4 Welding technique and materials 372 2
19.5 Mechanical and metallurgical testing of welds 374 43X
© Woodhead Publishing Limited, 2010