Joining of Cast ZE41A Mg to Wrought 6061 Al by the Cold Spray Process and Friction Stir Welding

Champagne, Victor K.; West, Michael; Rokni, Masoud; Curtis, Todd; McNally, Baillie

doi:10.1007/s11666-015-0301-8

Cited by 46 publications

(17 citation statements)

References 26 publications

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“…Experimental measurements of reduced oxide content in cold spray coatings as compared to initial powder feedstock underpins an argument for oxide layer breakup [22]. Small spherical ejecta found in the coating [20] or intermetallic detected at the interface [23] suggest localized melting or interdiffusion.…”

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confidence: 94%

Melting Can Hinder Impact-Induced Adhesion

et al. 2017

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Melting has long been used to join metallic materials, from welding to selective laser melting in additive manufacturing. In the same school of thought, localized melting has been generally perceived as an advantage, if not the main mechanism, for the adhesion of metallic microparticles to substrates during a supersonic impact. Here, we conduct the first in situ supersonic impact observations of individual metallic microparticles aimed at the explicit study of melting effects. Counterintuitively, we find that under at least some conditions melting is disadvantageous and hinders impact-induced adhesion. In the parameter space explored, i.e., ∼10 μm particle size and ∼1 km=s particle velocity, we argue that the solidification time is much longer than the residence time of the particle on the substrate, so that resolidification cannot be a significant factor in adhesion. DOI: 10.1103/PhysRevLett.119.175701 Understanding materials physics under impact has motivated extensive research in areas ranging from asteroid strikes [1] and ballistic deposition [2] to mechanochemical synthesis [3], materials failures [4,5], structural modification [6], and phase transformation [7]. Less conventionally, three decades ago, metallic powder particles were first observed to bond to metallic substrates under supersonicimpact conditions at low temperatures [8]. The notion of impact-induced adhesion, thereafter, has been implemented in powder processing through kinetic deposition or cold spray [9,10]. Kinetic deposition has proven successful in making coatings [11][12][13], in reclaiming damaged metallic surfaces [14], and in additively manufacturing bulk metallic materials [15].In this area of impact science, researchers have repeatedly observed a material-dependent critical velocity [16,17] [20] have been put forth to explain the underlying mechanism(s) of impact-induced adhesion, each of which enjoys partial support from observational data. For instance, sharp jumps observed in the temperature and strain in Lagrangian impact simulations have been used to support an argument for adiabatic shear localization [16,21]. Experimental measurements of reduced oxide content in cold spray coatings as compared to initial powder feedstock underpins an argument for oxide layer breakup [22]. Small spherical ejecta found in the coating [20] or intermetallic detected at the interface [23] suggest localized melting or interdiffusion.More consensus, however, has been attained around postmortem observations of material jets around the periphery of adhered particles [16,24,25]. We have recently, for the first time, conducted in situ observations of the impact behavior of individual supersonic metallic microparticles below and above the critical velocity and found that material ejection and jetting are crucial for adhesion [26,27]. We argued that neither shear localization nor melting are needed to account for material ejection. Rather, it can arise from the interaction of the impactinduced pressure wave with the contact periphery of the particle. A...

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confidence: 94%

Melting Can Hinder Impact-Induced Adhesion

et al. 2017

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“…Instead, they proposed that hydrodynamic jetting is formed as a result of strong pressure waves interacting with the expanding edge of the particle [10]. Moreover, mechanical interlocking [11][12][13], interfacial mixing [14,15], local melting [16], and diffusion [17] mechanisms also have been proposed to explain particle bonding formed during cold spray deposition. However, the topic on bonding mechanism in cold spray is still a mystery and needs further investigation.…”

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confidence: 99%

Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review

Sun

Tan

et al. 2020

Coatings

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Cold Gas Dynamic Spray or Supersonic Cold Spray, or simply ‘Cold Spray’, is an emerging technology for rapidly building thin films, thick coatings and large-scale additive manufacturing at relatively low temperatures. In a cold spray process, particles are accelerated to supersonic speeds by a propellant gas and impact a substrate, thus producing a strong bonding with the substrate and subsequently forming a deposit via layer-by-layer buildup. The scalability and low cost of this method make it promising for many applications in industry, such as metal component surface repair/enhancement/restoration and functional coatings for electrical, thermal, biomedical, energy storage, and nuclear plant applications. However, cold sprayed deposits usually require post process treatments to further modify their microstructures and mechanical properties in order to obtain the desired performances. A number of studies have been carried out on this topic. Here, recent progress in different post process treatments on cold sprayed deposits is reviewed, including heat treatment, friction-stir processing, shot peening, and laser re-melting. The effects of these post treatments on the microstructure, residual stress and mechanical properties of cold sprayed deposits are discussed.

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“…Previous researchers have focused their work on controlling the reaction between Mg and Al to a minimum level to minimize the formation of Mg-Al IMCs. The authors have used the following welding processes: TIG [4], spot welding [5], MIG [6], laser [7,8], laser-MIG hybrid [9], friction stir welding [10,11] and diffusion bonding [12] between others. However, the formation of Mg/Al IMCs is still.…”

Section: Introductionmentioning

confidence: 99%

Light-Weight Mg/Al Dissimilar Structures Welded by CW Laser for Weight Saving Applications

Gao

Meco

Wang

et al. 2017

Communications in Computer and Information Science

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With the increasing demand of lightweight alloys, such as magnesium (Mg) and aluminum (Al), the need for joining these two alloys is unavoidable. In this study, AZ31B Mg and 1060 Al alloys were joined by continuous wave laser micro-welding using a 0.05 mm thick Cu/Zn interlayer. The microstructure and phases constituent of the weld seam were examined by optical microscope, SEM and EDS. The formation and distribution of the intermetallic compounds (IMCs) and the relationship between these structures and the microhardness of the weld were discussed in detail. The effect of Cu/Zn interlayer on the performance of Mg/Al joint was also analyzed. The results showed that Mg/Al IMCs were formed in the weld, which indicates that the Cu/Zn foil could not prevent the reaction between Mg and Al. However, the addition of Cu and Zn into the weld pool refined the microstructure by improving the number of eutectic structures. The micro-hardness of Mg/Al IMCs in the middle of the weld was very high which can be detrimental to the toughness of the Mg/Al joints.

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Joining of Cast ZE41A Mg to Wrought 6061 Al by the Cold Spray Process and Friction Stir Welding

Cited by 46 publications

References 26 publications

Melting Can Hinder Impact-Induced Adhesion

Melting Can Hinder Impact-Induced Adhesion

Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review

Light-Weight Mg/Al Dissimilar Structures Welded by CW Laser for Weight Saving Applications

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