D.L. Chen

Microstructure and mechanical properties of dissimilar welded Mg-Al joints by ultrasonic spot welding technique

Abstract Dissimilar spot welds of magnesium–aluminium alloy were produced via a solid state welding process, i.e. ultrasonic spot welding, and a sound joint was obtained under most of the welding conditions. It was observed that a layer of intermetallic compound (IMC) consisting of Al12M17 formed at the weld centre where the hardness became higher. The lap shear strength and failure energy of the welds first increased and then decreased with increasing welding energy, with the maximum lap shear strength and failure energy occurring at ∼1250 J. This was a consequence of the competition between the increasing diffusion bonding arising from higher temperatures and the deterioration effect of the intermetallic layer of increasing thicknesses. Failure predominantly occurred in between the aluminium alloy and the intermetallic layer, which normally stayed at the magnesium side or from the cracks of the IMCs in the reaction layer.

Toughening mechanisms in iron-containing hydroxyapatite/titanium composites.

Pure hydroxyapatite (HA) is brittle and it cannot be directly used for the load-bearing biomedical applications. The purpose of this investigation was to develop a new iron-containing HA/titanium composite via pressureless sintering at a relatively low temperature with particular emphasis on identifying the underlying toughening mechanisms. The addition of iron to HA/titanium composites led to a unique and favorable core/shell microstructure of Ti-Fe particles that consisted of outer titanium and inner iron, and good interfacial bonding with HA matrix. While the relative density, hardness and Youngs modulus reduced, the flexural strength, fracture toughness, fatigue resistance, and the related fracture surface roughness increased significantly with increasing amount of Ti-Fe particles. Different toughening mechanisms including crack bridging, branching and deflection were observed in the composites, thus effectively increasing the crack propagation resistance and resulting in a substantial improvement in the mechanical properties of the composites.

Expulsion monitoring in spot welded advanced high strength automotive steels

Abstract Although there have been a number of investigations on monitoring and controlling the resistance spot welding (RSW) of low carbon galvanised steels, those of advanced high strength steels (AHSS) are limited. A data acquisition system was designed for monitoring weld expulsion via the measurement of voltage, current, electrode force and displacement and the calculation of resistance. The dynamic resistance, electrode force and tip displacement were characterised and correlated with the phenomenon of expulsion during RSW of dual phase (DP) steel using an ac welder. Two control strategies for DP600 spot welding were proposed on the basis of the rate of change in the dynamic resistance and the electrode force.

Improving weld strength of magnesium to aluminium dissimilar joints via tin interlayer during ultrasonic spot welding

Abstract Welding of magnesium to aluminium alloys is enormously challenging due to the formation of brittle Al12Mg17 intermetallic compounds (IMCs). This study was aimed at improving the strength of dissimilar joints of AZ31B-H24 magnesium alloy to 5754-O aluminium alloy by using a tin interlayer inserted in between the faying surfaces during ultrasonic spot welding. The addition of tin interlayer was observed to successfully eliminate the brittle Al12Mg17 IMCs, which were replaced by a layer of composite-like tin and Mg2Sn structure. Failure during the tensile lap shear tests occurred through the interior of the blended interlayer as revealed by X-ray diffraction and SEM observations. As a result, the addition of a tin interlayer resulted in a significant improvement in both joint strength and failure energy of magnesium to aluminium dissimilar joints and also led to an energy saving because the optimal welding energy required to achieve the highest strength decreased from ∼1250 to ∼1000 J.

Tensile Properties and Work Hardening Behavior of Laser-Welded Dual-Phase Steel Joints

The aim of this investigation was to evaluate the microstructural change after laser welding and its effect on the tensile properties and strain hardening behavior of DP600 and DP980 dual-phase steels. Laser welding led to the formation of martensite and significant hardness rise in the fusion zone because of the fast cooling, but the presence of a soft zone in the heat-affected zone was caused by partial vanishing and tempering of the pre-existing martensite. The extent of softening was much larger in the DP980-welded joints than in the DP600-welded joints. Despite the reduction in ductility, the ultimate tensile strength (UTS) remained almost unchanged, and the yield strength (YS) indeed increased stemming from the appearance of yield point phenomena after welding in the DP600 steel. The DP980-welded joints showed lower YS and UTS than the base metal owing to the appearance of severe soft zone. The YS, UTS, and strain hardening exponent increased slightly with increasing strain rate. While the base metals had multi-stage strain hardening, the welded joints showed only stage III hardening. All the welded joints failed in the soft zone, and the fracture surfaces exhibited characteristic dimple fracture.

Welding behaviour, microstructure and mechanical properties of dissimilar resistance spot welds between galvannealed HSLA350 and DP600 steels

Abstract Resistance spot welding experiments were conducted on dissimilar material combination of HSLA350/DP600 steels. The welds were characterised using optical and scanning electron microscopy. The fusion zone of the dissimilar material spot weld was predominantly martensitic with some bainite. Mechanical properties were also determined by tensile shear, cross tension and fatigue tests. The performance of dissimilar material spot weld was different from that of the similar ones in each of the HSLA350 and DP600 steels and exhibited different heat affected zone hardness. The DP600 weld properties played a dominating role in the microstructure and tensile properties of the dissimilar material spot welds. However, the fatigue performance of the dissimilar welds was similar to that of the HSLA350 welds. Fatigue tests on the dissimilar material spot welds showed that the 5·5 mm diameter nugget exhibited higher fatigue strength than the 7·5 mm diameter nugget.

Contribution of the cyclic loading portion below the opening load to fatigue crack growth

A simple test procedure involving stress ratio changes at the fatigue threshold is proposed to reveal the role of the lower portion of the loading cycle below Kop in the fatigue crack growth behaviour. It is observed for both Al 2024-T3 and Al 7475-T761 alloys that the initially non-propagating fatigue crack at the fatigue threshold resumes growth upon diminishing Kmin while keeping Kth,max constant. These experimental findings can be interpreted by means of a modified crack closure concept in which the contribution of the lower portion of the loading cycle below Kop (including also a part of compressive loading if R < 0) to the variation in the stress state experienced by the fatigue crack tip is taken into account.

A model for crack closure

The current status of the knowledge about the fatigue crack closure effect is briefly reviewed. A nodel for fatigue crack closure process is proposed, which involves an elastic wedge placed into an elastic crack to simulate the obstruction of crack closure due to asperities or oxide debris. Linear elastic fracture mechanics is applied to calculate the relations between the externally applied stress and the crack opening displacement (COD) for both the closure-free and the closure-affected cases. The slope of the stress-COD response for the closure-affected case is indicated to be larger than that for the closure-free case, depending on the fracture surface topography. Based on the difference in the stress-COD responses, an alternative definition of the fatigue crack closure effect is proposed. The difference in the externally applied stress intensities for the closure-free and closure-affected cases at the minimum applied stress is defined as shielding stress intensity range †Ksh. The actual stress intensity transmitted to the crack tip at the minimum applied stress is used to replace the conventional Kop value. The theoretical calculation indicates that the conventionally defined Kop value merely expresses an extreme case of Kmin,act for an infinitely hard or infinitely wide wedge, which is practically non-existent in engineering materials. Thus, the application of the Kop value underestimates the effective stress intensity range experienced by the fatigue crack tip. The results obtained from the current considerations are discussed and compared with those described in the literature.

Fatigue crack growth behavior of X2095 Al–Li alloy

Abstract Microstructures and micro-textures of X2095 Al–Li alloy in as-received/superplastic state were characterized by means of SEM/BDS, X-ray diffraction and orientation imaging microscopy (OIM). It was observed that the microstructure of the alloy was typical of a particulate-reinforced composite material, consisting of aluminum matrix and homogeneously distributed TB(Al7Cu4Li) particles with a volume fraction of about 10%. Brass-type texture was the dominant texture component. Both constant amplitude and near-threshold fatigue crack growth rates of the alloy in the L–T and T–L orientations were determined at different stress ratios. Particular attention was paid to the role of the TB phase in the fatigue crack growth. When a fatigue crack approached a TB particle, the crack basically meandered to avoid the particle. The TB particles thus provided a strong resistance to the propagation of fatigue crack by promoting crack deflection and the related crack closure effects. The fatigue crack propagation behavior has been explained by the microstructural features, micro-textures, cracking characteristics and crack closure effects.

A Unified Model for the Prediction of Yield Strength in Particulate-Reinforced Metal Matrix Nanocomposites

Lightweighting in the transportation industry is today recognized as one of the most important strategies to improve fuel efficiency and reduce anthropogenic climate-changing, environment-damaging, and human death-causing emissions. However, the structural applications of lightweight alloys are often limited by some inherent deficiencies such as low stiffness, high wear rate and inferior strength. These properties could be effectively enhanced by the addition of stronger and stiffer reinforcements, especially nano-sized particles, into metal matrix to form composites. In most cases three common strengthening mechanisms (load-bearing effect, mismatch of coefficients of thermal expansion, and Orowan strengthening) have been considered to predict the yield strength of metal matrix nanocomposites (MMNCs). This study was aimed at developing a unified model by taking into account the matrix grain size and porosity (which is unavoidable in the materials processing such as casting and powder metallurgy) in the prediction of the yield strength of MMNCs. The Zener pinning effect of grain boundaries by the nano-sized particles has also been integrated. The model was validated using the experimental data of magnesium- and titanium-based nanocomposites containing different types of nano-sized particles (namely, Al2O3, Y2O3, and carbon nanotubes). The predicted results were observed to be in good agreement with the experimental data reported in the literature.