Friction joining techniques, such as Friction Stir Spot Welding (FSSW) and high power Ultrasonic Welding (USW), could offer a solution for joining dissimilar materials combinations, such as aluminium (Al) to magnesium (Mg), where high intermetallic reaction rates make the use of conventional joining techniques problematic. Ultrasonic welds have been produced between 1 mm gauge Al 6111-T4 and Mg AZ31-H24 sheets, and the interfacial reaction has been studied as a function of welding time. For this welding system, the mechanical properties of the joints were optimised when a double reed welding system was employed to join materials that had been prepared using 800 grit SiC paper under a clamping force of 1.9 kN, and when the materials were oriented with the rolling direction parallel to the vibration direction. Welds produced between Al and Mg achieved similar peak lap shear strengths to those produced between Mg and Mg at welding times of 0.4 s, but the failure energy of the Al-Mg welds was less than half that of the parent material. In addition, the Al-Mg welds always failed at the interface between the sheets, rather than the desirable, and more energy intensive, pullout mechanism. The inferior mechanical properties were attributed to the rapid formation of a brittle intermetallic layer that initially formed as islands of the γ-Al12Mg17 phase. These islands rapidly spread and became continuous within 0.3 s of welding time, at which point a second sublayer of the β-Al3Mg2 phase began to form on the Al side of the intermetallic reaction layer. The combined layers reached a total thickness of 20 µm within 0.9 s of welding time, with the β-Al3Mg2 sublayer becoming the thicker of the two by this point. At longer welding times, interface liquation was observed at temperatures below the recognised lowest temperature eutectic reaction in the Al-Mg binary phase diagram. This was the result of the alloying elements present in the system and there was no depression in the melting point as a result of the high strain rate associated with this process, as has been proposed elsewhere. The rate of growth of the intermetallic layer during welding was higher than in static heat treatments, which was most likely due to the deformation causing microcracking in the brittle intermetallic layer, allowing short circuit diffusion to occur, and enhancing the growth rate by a factor of approximately 2. Finally, attempts were made to limit the rate of intermetallic compound (IMC) formation by applying coatings to the Mg sheet. The effect of the coatings was to reduce the overall IMC layer thickness by 50 %.

Les travaux concernent l'étude de l’assemblage dissimilaire d’alliages d'aluminium (Al4043, Al5356) et de magnésium (RZ5, AZ31) par les procédés CMT et laser. La méthode des plans d'expériences statistiques a été mise en oeuvre afin d'analyser les effets des paramètres opératoires de soudage et la nature chimique des substrats et des fils d’apport. Les effets chimiques, thermomécaniques et énergétiques ont été étudiés dans l'objectif de contrôler et de diminuer l’épaisseur de la couche intermétallique formée entre la zone fondue et le métal de base et considérée comme critique pour la fissuration. La microstructure a été caractérisée par microscopie optique, MEB, EDS, rayons X, dureté et nano-indentation.La rupture dans la couche d’interface est liée à la formation de composés intermétalliques (Al3Mg2, Al12Mg17), d'une dureté jusqu’à 350 HV0,025, ainsi qu'à l'épaisseur de la couche et des éléments d'alliage. Le RZ5 a été assemblé avec succès avec le fil d’apport Al4043 par les deux procédés CMT et laser.Suite à l’analyse systématique des résultats, qui montre un meilleur comportement d’Al4043/RZ5 qui contient du zirconium, l'ajout de cet élément dans la zone fondue a permis de montrer une amélioration de la qualité des joints par effet sur la microstructure.Pour l’assemblage laser, une modification des conditions des vitesses de refroidissement par un pompage thermique plus rapide par l’utilisation d’un support de plaques de cuivre a induit une modification des couches d'interface et montre tout l'intérêt de maîtriser les conditions opératoires. Par ailleurs, une vibration ultrasonore des substrats a été testée pour modifier la formation des zones problématiques / This work concern a study of the dissimilar joining of aluminium (Al4043, Al5356) and magnesium (RZ5, AZ31) by CMT and laser welding process. The method of statistical design of experiments has been implemented in order to analyse the effects of the technological welding parameters and the chemical nature of the base and filler metal. The chemical, thermo-mechanical and energetic effect were studied with the aim to control and decrease the thickness of the intermetallic layer formed between the melted zone and the base metal and considered to be critical to cracking. The microstructure was studied by optical and SEM microscopy, EDS, X-ray, hardness and nanoindentation.The fracture produced in the interface layer has been related to the intermetallic compounds (Al3Mg2 and Al12Mg17), with a hardness up to 350 HV0.025, as well of the thickness of the interface layer and to the alloying composition. The RZ5 as base metal was successfully joined with the Al4043 welding wire, in both CMT and laser process.According to the systematically analyse, who shows a better welding ability of the couples Al4043/RZ5, which contains zirconium, by the adding of this element in the molten metal the welding ability improvement was showed.For the laser joining, a modification of the cooling condition by a accelerate thermal cycle, by using a copper support for the base metal was induce a modification of the interface layer, showing the interest of mastering the technical condition. Moreover, a ultrasonically vibration of the base metal was tested in attempting to modify the formation of the problematical zones

Combinations of different materials are increasingly used in the modern engineering structures. The driving forces of this trend are rising fuel costs, global warming, customer demands and strict emission standards. Engineers and industries are forced to improve fuel economy and cut emissions by introducing newly design engines and lightweighting of structural components. The use of lightweight materials in the structures has proved successful to solve these problems in many industries especially automobile and aerospace. However, industry still lacks knowledge how to manufacture components from polymeric materials in combination with metals where significant differences exist in properties. This thesis aims to demonstrate and generate the methodology and guidelines for hybrid joining of aluminium alloys to thermoplastics using friction stir welding. The developed technique was identified, optimized and evaluated from experimental data, metallography and mechanical characterization. The success of the technique is assessed by benchmarking with recent literatures. In this work, lap joints between aluminium alloys (AA5754, AA6111) and thermoplastics (PP, PPS) were produced by the friction stir welding technique. The specimens were joined with the friction stir welding tools under as-received conditions. Metallic chips were generated and merged with the molten thermoplastic to form a joint under the influence of the rotating and translating tool. The effects of process parameters such as rotational speed, translational speed and distance to backing were analyzed and discussed. The investigation found joint strength was dominated by mechanical interlocking between the stir zone and the aluminium sheet. The results also show that the joint strength is of the same order of magnitude as for other alternative joining techniques in the literature. / <p>QC 20150908</p>

No description available.

Multi-material structures are increasingly used in vehicle bodies to reduce weight of cars. The use of these lightweight structures is driven by requirements to improve fuel economy and reduce CO2 emissions. The automotive industry has replaced conventional steel components by lighter metals such as aluminium alloy. This is done together with cutting weight of structures using more advanced strength steels. However, sound joining is still difficult to achieve due to differences in chemical and thermal properties.   This research aims to develop a new innovative welding technique for joining aluminium alloy to ultra-high strength steels. The technique is based on friction stir welding process while the non-consumable tool is made of an ordinary tool steel. Welding was done by penetrating the rotating tool from the aluminium side without penetrating into the steel surface. One grade of Al-Mg aluminium alloy was welded to ultra-high strength steels under lap joint configuration. Different types of steel surface coatings including uncoated, hot-dipped galvanised and electrogalvanised coating have been studied in order to investigate the influence of zinc on the joint properties. The correlation among welding parameters, microstructures, intermetallic formation and mechanical properties are demonstrated in this thesis.  Results have shown that friction stir welding can deliver fully strong joints between aluminium alloy and ultra-high strength steels. Two intermetallic phases, Al5Fe2 and Al13Fe4, were formed at the interface of Al to Fe regardless of surface coating conditions. The presence of zinc can improve joint strength especially at low heat input welding due to an increased atomic bonding at Al-Fe interface. The formation of intermetallic phases as well as their characteristics has been demonstrated in this thesis. The proposed welding mechanisms are given based on metallography investigations and related literature. / <p>QC 20170519</p>

No description available.

La présente étude est dédiée à la compréhension des mécanismes de malaxage intervenant lors du soudage de matériaux dissimilaires par des sources de haute énergie et en particulier sur deux couples de matériaux présentant des problèmes métallurgiques différents : • cuivre - inox (lacune de miscibilité, différence de propriétés thermophysiques),• TA6V- inox (oxydation, formation de phases intermétalliques fragilisant la soudure).Pour le premier couple de matériaux, le soudage par laser Nd:YAG continu et par faisceau d'électrons a été utilisé. L'étude des évolutions de la morphologie des soudures, de la composition et de la microstructure des zones fondues ainsi que des propriétés mécaniques a permis de proposer des hypothèses sur les mécanismes de formation du mélange hétérogène à solubilité limitée. Afin de quantifier les phénomènes physiques intervenant en soudage continu de matériaux dissimilaires, la modélisation numérique a été mise en œuvre en utilisant le logiciel FEM "Comsol Multiphysics". Une série des modèles simulant les champs de températures, les mouvements convectifs et le malaxage (diffusion, méthode level set, méthode des champs de phases) a été créée. Dans le cas du laser, la formulation pseudo-stationnaire du transfert de chaleur basée sur la géométrie du capillaire simplifiée et la convection a été couplée avec les problèmes 2D de diffusion et de malaxage des matériaux dans différents plans horizontaux. En soudage par faisceau d'électrons, la morphologie de la microstructure a nécessité une formulation temporelle. Le modèle multiphysique final en couplage complet (solution multiphysique simultanée) reproduit le processus de formation d'une structure périodique de solidification lors du soudage par faisceau d'électrons et permet d'expliquer l'aspect des structures alternées entre matériaux immiscibles ou présentant de grandes différences de propriétés thermophysiques.Le deuxième couple de matériaux présente des problèmes métallurgiques majeurs liés à la formation des phases intermétalliques rendant l'assemblage direct par fusion impossible. La composition locale devient donc l'aspect-clef de la formation d’une soudure correcte : l'introduction d’un troisième matériau (cuivre) ayant une meilleure compatibilité avec le titane est nécessaire. Pour pouvoir déterminer les fenêtres optimales des conditions opératoires, les modèles numériques, créés précédemment, ont été adaptés pour quatre procédés de l’assemblage : faisceau d'électrons, soudage lasers Nd:YAG continu et pulsé, brasage par laser avec apport de fil. L'analyse élémentaire des microstructures dans les soudures résistantes mécaniquement a permis de développer le scénario de la solidification d'une zone fondue et de comprendre l'influence de la composition aux interfaces sur la résistance mécanique des assemblages.Les modèles numériques multiphysiques créés au cours de cette étude permettent l'accès rapide à la grande quantité d'information sur le comportement de la zone fondue en fonction des paramètres de soudage en se basant sur le nombre des données de départ relativement limité et sur quelques hypothèses simplificatrices. L'approche multiphysique à la modélisation de soudage permet de reproduire la forme de la zone fondue, visualiser les écoulements du liquide et cartographier la distribution de certains éléments avec une bonne corrélation avec les résultats expérimentaux. L'ensemble des modèles permet de déterminer les conditions opératoires répondant aux critères fixes en fonction de la métallurgie d'un couple hétérogène. / The present study is dedicated to the comprehension of the mechanism of materials mixing during dissimilar welding by high power beam sources. We have been interested in joining of two couples of metallic materials which present different metallurgical problems: • copper- stainless steel (miscibility gap, important difference in physical properties);• TA6V- stainless steel (oxidation on air, formation of intermetallic phases which made the joint brittle).For the first couple of materials, continuous laser Nd:YAG welding and electron beam welding have been applied. The experimental study of morphology evolution, composition, microstructure and mechanical properties has allowed establishing the hypotheses on formation of heterogeneous mixture between the materials having limited solubility. To quantify the physical phenomena of continuous dissimilar welding, the numerical modeling has been carried out by means of FEM software package "Comsol Multiphysics". A number of models reproducing temperature field, convection movements and mixing (diffusion, level set method, phase field method) between the materials has been created. In case of continuous laser welding, the pseudo-stationary formulation of heat transfer based on simplified key-hole geometry and convection has been coupled with two-dimensional problems of diffusion and mixing in horizontal planes. The electron beam welding presenting the nonlinear development of the weld has needed employing of temporary formulation. Final model including complete coupling (simultaneous multiphysical solving) reproduces the process of development of periodic solidification structure during electron beam welding and allows explaining the mechanism of formation of altered structures between immiscible materials which have important difference in thermophysical properties.The second couple of materials presents weldability problems due to formation of brittle intermetallic phases making direct joining by fusion impossible. The local elementary composition becomes the key-aspect of successful joining: the introduction of the third material (pure copper) having better compatibility with titanium is necessary. To determine the ranges of optimal operational conditions, numerical models created previously have been adapted to the case of four joining techniques: electron beam and laser Nd:YAG (continuous and pulsed) welding and laser brazing with filler wire. Elementary analysis of microstructures of resistant welds has allowed developing the solidification scenario and understanding the influence of local composition of heterogeneous interfaces on tensile properties of the joints. The multiphysical models created during this study allow rapid access to high quantity of data on behavior of melted zone in function of welding parameters basing on relatively limited input data and several simplification hypotheses. The multiphysical approach to welding modeling allows recreating the shape of melted zone, to visualization the convection movements and providing the cartography of several elements in good correspondence with experimental results. A set of models allows determination of operational parameters respecting fixed criterions determined by metallurgy of dissimilar couple.