Since the importance of magnesium alloys has increased during recent years there is an intense need for appropriate joining technologies. This concerns the joining of both similar and dissimilar materials (such as magnesium and aluminium, for instance). Welding technologies offer a broad range of joining parameters, [1] but they are not appropriate, in most of the cases, for joining highly alloyed materials and joining dissimilar materials. Only beam welding and friction welding can be used for joining dissimilar materials. [2] The main drawback of welding processes is the high temperature load of the base materials. Mechanical joining can cause corrosion problems if ferrous joining elements are used, for instance. Thus, alternative low-heat joining technologies for joining magnesium alloys both to each other and to aluminum alloys are examined in the present study.Appropriate filler materials for soldering magnesium are not available. Therefore, new filler metals have to be developed. Zn-Mg-Al based alloys offer a high potential since they possess a low electrochemical difference in comparison to the magnesium based material, on one hand. On the other hand, they are well suited from the metallurgical point of view. Soldering temperatures are about 350°C. Thus, the filler materials can be applied to many of the magnesium-based alloys.Amorphous magnesium-based alloys were investigated already during several studies. e.g. [3][4][5][6] The aim was to get better mechanical properties in comparison to crystalline magnesium alloys. It was found that the crystallization behaviour depends very strongly on the amount of additional alloying elements.The filler metals are produced as amorphous tapes, since solidification at non-equilibrium conditions results in a new structure and, thus, the mechanical properties are completely different. Since amorphous filler tapes are very elastic they have been known for a long time to be much easier to handle during the application to the soldering gap than are crystalline filler metals are. Having a defined thickness, the tapes offer an additional advantage since the soldering or brazing gap can be adjusted very easily. [7] The production of amorphous tapes is already common for nickel based or copper based filler metals, for instance. It has been shown [8] that the use of amorphous filler materials results in finer microstructures and a minimization of intermetallic phases after soldering in comparison to the use of crystalline fillers. Another advantage of amorphous filler metals is that they posses very good homogeneity.
Experimental ProcedureA filler alloy composition containing 55 mass-% Zn, 42 % Mg, and 3 % Al was produced by continuous casting using an S8-midi machine (Frisch GmbH). The alloys were induction heated to a temperature of 650°C and afterwards directly casted into a cylindrical die. Argon was used as a protective gas during the whole process. The rods have a diameter of 14 mm. The elemental composition was examined using electron diffraction X-ray spectroscopy (EDXS...