Influencing mechanism of pre-existing nanoscale Al5Fe2 phase on Mg-Fe interface in friction stir spot welded Al-free ZK60-Q235 joint

doi:10.1016/j.jmst.2019.12.003

Abstract

Abstract:

Al-free ZK60 magnesium (Mg) alloy sheet was selected as substrate material of Mg-steel pinless friction stir spot welding (FSSW), avoiding the effect of the Al element in the substrate on the alloying reaction of Mg-iron (Fe) interface. The sound FSSW joint of ZK60 Mg alloy and Q235 steel with a hot-dipped aluminum (Al)-containing zinc (Zn) coating was successfully realized. The detailed microstructural examinations proved that Al₅Fe₂ phase at the Mg-Fe interface came from the pre-existing Al₅Fe₂ phase in the coating and acted as the transition layer for promoting the metallurgical bonding of Mg and Fe. The interfaces with well-matched lattice sites among Fe, Al₅Fe₂ and Mg were formed during FSSW. A low energy interface with good match of lattice sites ((002)_Al5Fe2//(110)_Fe, [110]_Al5Fe2//[$\bar{1}$13]_Fe) between Al₅Fe₂ and Fe was identified. For the interface between Al₅Fe₂ and Mg, an orientation relationship of (6$\bar{2}$2)Al5Fe2//(3$\overline{112}$)Mgand[1$\overline{58}$]Al5Fe2//[2$\bar{4}$23]Mg was observed. The tensile-shear load of the ZK60-steel joint could reach 4.6 kN. Moreover, the joint fracture occurred at the interface between the Al₅Fe₂ layer and the Mg alloy substrate, suggesting the brittle fracture characteristic.

Key words: Dissimilar welding, Friction stir spot welding, Magnesium alloys, Steels, Zinc coating

R.Z. Xu, Q. Yang, D.R. Ni, B.L. Xiao, C.Z. Liu, Z.Y. Ma. Influencing mechanism of pre-existing nanoscale Al₅Fe₂ phase on Mg-Fe interface in friction stir spot welded Al-free ZK60-Q235 joint[J]. J. Mater. Sci. Technol., 2020, 42: 220-228.

Figures/Tables 12

Fig. 1. Schematic of ZK60-steel FSSW and position of temperature measurement.

Fig. 2. (a) SEM micrograph of coating surface on Q235 steel and (b) EDS spectra obtained from zone B in Fig. 2(a).

Fig. 3. (a) SEM micrograph of cross-sectioned Zn-Al coated steel and (b) elemental analysis of black line in Fig. 3(a).

Fig. 4. XRD patterm of Zn-Al coated steel surface after etching by fuming HNO3.

Fig. 5. (a) Typical cross-section photograph of FSSW ZK60-steel joint using pinless tool, and microstructures and elemental line analyses of different zones in Fig. 5(a): (b) region B and (d) line D; (c) region C and (e) line E.

Fig. 6. (a) HAADF-STEM image of Mg-steel interface of FSSW ZK60-steel joint, (b) elemental distribution of Mg, Fe, Zn and Al, (c) EDS spectra and (d) typical SADP obtained from transition region in Fig. 6(a).

Fig. 7. Electron diffraction patterns taken from (a) Fe2Al5/Fe and (b) Fe2Al5/Mg interfaces, with incident beam parallel to [-113]Fe and [110]Al5Fe2 in (a) and [1-5-8]Al5Fe2 and [223]Mg in (b), respectively.

Fig. 8. Load-displacement curve of FSSW ZK60-steel joint.

Fig. 9. (a) Typical fracture location of FSSW ZK60-steel joint, (b) SEM image of facture surface and (c) magnified graphs of region C in Fig. 9(b) and EDS spectra obtained from (d) region D and (e) region E in Fig. 9(c).

Fig. 10. Temperature profiles of locations A and B during FSSW of ZK60 and steel.

Table 1 Possible matching planes and directions of Fe2Al5 and Mg in FSSW.

Matching planes or directions	(021)_Al5Fe2 //(0002)_Mg	(002)_Al5Fe2 //(01-1-2)_Mg	(62-2)_Al5Fe2 //(3-1-1-2)_Mg	[0-10]_Al5Fe2 //[4-2-20]_Mg	[1-12]_Al5Fe2 //[4-2-20]_Mg	[1-5-8]_Al5Fe2 //[2-423]_Mg
d_Al5Fe2 (nm)	0.255	0.211	0.103	0.642	0.654	0.049
d_Mg (nm)	0.261	0.190	0.097	0.642	0.642	0.072
Mismatch (%)	2.3	10.5	6.0	0	1.9	38

Fig. 11. Schematic of Zn-Al coating evolution of typical FSSW ZK60-steel joint: (a) movement of Zn-Al coating; (b) formation of joint; (c) failure location; (d) movement of Zn atom during FSSW; heterophase interfaces of (e) Fe2Al5/Mg and (f) Fe2Al5/Fe after FSSW.

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Influencing mechanism of pre-existing nanoscale Al₅Fe₂ phase on Mg-Fe interface in friction stir spot welded Al-free ZK60-Q235 joint

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