Electron beam surface heating-diffusion bonding: An effective joining method for aluminum alloy metal-matrix composite with high SiC volume

doi:10.1016/j.jmst.2021.01.081

Abstract

Abstract:

As a novel method to reduce the temperature during electron beam welding, and to subsequently inhibit interfacial reaction between SiC and Al matrix, the electron beam surface heating - diffusion bonding is proposed for joining SiC particle reinforced aluminum alloy metal - matrix composite of 45 vol.% SiC/2024 Al. The defocused electron beam was used to heat the base metal surface, and the simultaneous pressure was applied to the butt surface to achieve bonding. The base metals were successfully joined by diffusion. The maximum temperature of the whole joint was effectively decreased to less than 650 ℃. The Gibbs free energy change of interfacial reaction was calculated, meaning a positive value reaching 218 kJ/mol and a consequently prominent inhibitory effect on the formation of brittle Al₄C₃ that was proved by microstructural observation. The tensile strength for the bonded joint was increased by 35 % compared to that for ordinary welded joint. When the TC4 layer was added, TiC strengthening particles were formed with the deficiency of Al₄C₃, corresponding to the significantly increased tensile strength of 63 % of base metal (154 MPa).

Key words: 45 vol.% SiC/2024 Al, Electron beam surface heating-diffusion bonding, Interfacial reaction inhibition, Gibbs free energy change

Guoqing Chen, Qianxing Yin, Jian Cao, Ge Zhang, Gongbo Zhen, Binggang Zhang. Electron beam surface heating-diffusion bonding: An effective joining method for aluminum alloy metal-matrix composite with high SiC volume[J]. J. Mater. Sci. Technol., 2021, 88: 109-118.

Figures/Tables 13

Fig. 1. Heat-transfer mechanism for (a) Direct EBW, and (b) EBSH - diffusion bonding.

Table 1 Chemical composition of 2024 Al matrix (in wt%).

Element	Cu	Mg	Si	Fe	Ni	Zn	Cr	Al
Percentage	3.8-4.9	1.2-1.8	0.5	0.5	0.5	0.25	0.1	Bal.

Fig. 2. Welding diagram for EBSH - diffusion bonding.

Fig. 3. Cross-sectional morphology of the EBSH - diffusion bonded joint: (a) General morphology, and (b) Microstructure, (c) Coarsened SiC in the small fusion zone at top surface, and (d) Fine dispersed SiC in the diffusion zone. Temperature diagram for the EBSH - diffusion bonded joint calculated by ABAQUS: (e) Cross-sectional temperature field, (f) Temperature-time curve at the midpoint along beam movement direction, and (g) Temperature-distance curve.

Table 2 Value of parameters in equation [22].

Fig. 4. TEM results of the diffusion zone: (a) General morphology, (b) SiC labeled as zone A, (c) Eutectic α-Al?+?Al2Cu labeled as zone B, and (d) Al2CuMg labeled as zone C.

Fig. 5. Line scanning results for Mg in the cross section of joints.

Fig. 6. Results for fracture morphology: (a) Direct welded joint, (b) Fusion zone of EBSH - diffusion bonded joint, and (c) Diffusion zone of EBSH - diffusion bonded joint.

Fig. 7. Cross-sectional morphology of EBSH - diffusion bonded joint with TC4 interlayer: (a) General morphology, and microstructure of (b) Fusion zone and (c) Diffusion zone. (d) XRD result for EBSH - diffusion bonded joint.

Fig. 8. Precipitated phases within (a) Fusion zone, (b) Interlayer and (c) Diffusion zone.

Table 3 EDS results for precipitated phases (in at.%).

Element	C	Al	Ti	Si	V
A	38.87	5.88	16.35	38.22	0.68
B	23.11	39.23	33.06	2.65	1.95
C	36.19	3.71	40.99	18.27	0.84
D	35.33	8.01	37.15	18.22	1.29
E	42.36	8.78	7.90	40.59	0.37

Fig. 9. TEM results for EBSH - diffusion bonded joint with TC4 interlayer: (a) TiC particles, (b) Al3Ti?+?TiC, (c) SiC with Al matrix, and (d) Ti5Si3 particle.

Fig. 10. (a) Tensile strength of joint acquired by different method. Fracture morphology of EBSH - diffusion bonded joint with TC4 interlayer: (b) Fusion zone and (c) Diffusion zone.

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