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<p>Friction stir welding (FSW), a novel solid-state joining technology, has demonstrated distinct advantages for welding dissimilar magnesium/aluminum alloys due to the lower heat input. To address the deterioration of mechanical properties caused by brittle intermetallic compounds (IMCs) in Mg/Al welded joints, the study introduces AlCoCrFeNi high-entropy alloy (HEA) powder as the interlayer. By regulating the depth of pre-prepared grooves filled with powder on the aluminum plate, the barrier effect of HEA on the Mg/Al interface and the optimization mechanism for the microstructure were investigated. The results indicated that with groove depth of 0.1&#xa0;mm, the joint achieved the highest average tensile strength of 36.99&#xa0;MPa, which is 24.3% higher than that of the sample without an interlayer. The implantation of HEA particles improves the fluidity of materials, facilitates the mechanical interlocking at the Mg-Al interface, and suppresses the formation of a continuous IMC layer. The fracture location shifted from the interface to the magnesium alloy side. Additionally, the hardness of the stir zone was significantly higher than that of the joint without the interlayer.</p>

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A High-Entropy Alloy Powder-Assisted Friction Stir Lap Welding Approach for Magnesium-Aluminum Dissimilar Alloys

  • 期刊论文

  • 发表日期：

    2025年12月10日

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  • Yibo Sun,
  • Zhuoer Yan,
  • Bo Yu,
  • Jianning Zhu,
  • Libin Fu

摘要

Friction stir welding (FSW), a novel solid-state joining technology, has demonstrated distinct advantages for welding dissimilar magnesium/aluminum alloys due to the lower heat input. To address the deterioration of mechanical properties caused by brittle intermetallic compounds (IMCs) in Mg/Al welded joints, the study introduces AlCoCrFeNi high-entropy alloy (HEA) powder as the interlayer. By regulating the depth of pre-prepared grooves filled with powder on the aluminum plate, the barrier effect of HEA on the Mg/Al interface and the optimization mechanism for the microstructure were investigated. The results indicated that with groove depth of 0.1 mm, the joint achieved the highest average tensile strength of 36.99 MPa, which is 24.3% higher than that of the sample without an interlayer. The implantation of HEA particles improves the fluidity of materials, facilitates the mechanical interlocking at the Mg-Al interface, and suppresses the formation of a continuous IMC layer. The fracture location shifted from the interface to the magnesium alloy side. Additionally, the hardness of the stir zone was significantly higher than that of the joint without the interlayer.