This research demonstrates the use of friction stir welding (FSW) to join dissimilar (Al-Mg) metal alloys. The main challenges in joining different, dissimilar metal alloys is the formation of brittle intermetallic compounds (IMCs) in the stir zone affecting mechanical properties of joint significantly. In this present study, FSW joining process is used to join aluminum alloy AA2139 and magnesium alloy WE43. The 9.5 mm thick plates of AA2139 and WE43 were friction stir butt welded. Different processing parameters were used to optimize processing parameters. Also, various weldings showed a crack at interface due to formation of IMCs caused by liquation during FSW. A good strength sound weld was obtained using processing parameter of 1200 rev/min rotational speed; 76.2 mm/min traverse speed; 1.5 degree tilt and 0.13 mm offsets towards aluminum. The crack faded away as the tool was offset towards advancing side aluminum. Mostly, the research was focused on developing high strength joint through microstructural control to reduce IMCs thickness in Al-Mg dissimilar weld joint with optimized processing parameter and appropriate tool offset.

Acoustics is the study of all sound waves, with ultrasound classified as those frequencies above 20,000 Hz. Currently, ultrasound is being used in many industries for a variety of purposes such as ultrasonic imaging, ultrasonic assisted friction stir welding, and ultrasonic spot welding. Despite these uses, the effects of ultrasound on phase stability and resultant mechanical properties has been minimally analyzed. Here we study the impact waves play in ultrasonic welding and design an apparatus to maximize waves entering aluminum alloy samples. Aluminum 2139 and 7050 are used because they are precipitation strengthened by metastable phases so temperature change, and the corresponding phase stability, can greatly impact their strength. Results suggest that the ultrasonic welder primarily imposes a localized temperature spike due to friction, averaging over 200°C in a few seconds, which generally lowers the Vickers hardness due to coarsening or even dissolution of strengthening precipitates. Conversely, the new design increases the Vickers hardness by up to 30% over the initial hardness of approximately 63HV for aluminum 2139 and 83HV for aluminum 7050, respectively, while only increasing the temperature by an average of approximately 10°C. This new design was unable to achieve peak hardness, but the strengthening it achieved in two minutes was equivalent to one month of natural aging. If this system was able to be fine-tuned, it could serve as a quick strengthening process for recently weakened aluminum alloys, such as after friction stir welding.