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<p>Aluminium and magnesium are becoming more popular as structure materials due to the automobile industry’s requirement to increase the usage of lightweight construction. This study explores the mechanical properties of friction crush welded aluminum-magnesium joints enhanced by a zinc interlayer. The research systematically analyzes the influence of tool geometry, feed rate, rotational speed, and the zinc layer on weld integrity. A novel finite element (FE) model was developed in ABAQUS to simulate the welding process, with its accuracy validated through infrared thermography. The simulated temperature distribution closely matched experimental results, confirming model reliability. Microstructural analysis using Field Emission Scanning Electron Microscopy (FE-SEM), Energy Dispersive Spectroscopy (EDS) for chemical characterization, and phase identification through X-ray Diffraction (XRD) provided insights into intermetallic compound (IC) formation. The optimal input variables were anticipated to produce the highest tensile strength feasible for the welded workpiece. Microhardness testing revealed a non-uniform hardness distribution across the joint. Experimental findings emphasized that tool rotational speed (77.23%) had the most pronounced effect on joint strength, followed by feed rate (7.85%), tool geometry (6.34%), and the zinc interlayer (2.37%). These results offer valuable guidance for optimizing welding parameters, advancing lightweight structural applications through enhanced joint performance.</p>

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Parametric investigation into friction crush welding of dissimilar aluminium 5052 and magnesium AZ31 joint with zinc interlayer

  • 期刊论文

  • 发表日期：

    2025年5月6日

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  • Ashu Kumar,
  • Gurinder Singh Brar

摘要

Aluminium and magnesium are becoming more popular as structure materials due to the automobile industry’s requirement to increase the usage of lightweight construction. This study explores the mechanical properties of friction crush welded aluminum-magnesium joints enhanced by a zinc interlayer. The research systematically analyzes the influence of tool geometry, feed rate, rotational speed, and the zinc layer on weld integrity. A novel finite element (FE) model was developed in ABAQUS to simulate the welding process, with its accuracy validated through infrared thermography. The simulated temperature distribution closely matched experimental results, confirming model reliability. Microstructural analysis using Field Emission Scanning Electron Microscopy (FE-SEM), Energy Dispersive Spectroscopy (EDS) for chemical characterization, and phase identification through X-ray Diffraction (XRD) provided insights into intermetallic compound (IC) formation. The optimal input variables were anticipated to produce the highest tensile strength feasible for the welded workpiece. Microhardness testing revealed a non-uniform hardness distribution across the joint. Experimental findings emphasized that tool rotational speed (77.23%) had the most pronounced effect on joint strength, followed by feed rate (7.85%), tool geometry (6.34%), and the zinc interlayer (2.37%). These results offer valuable guidance for optimizing welding parameters, advancing lightweight structural applications through enhanced joint performance.