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1 Related titles: Failure mechanisms of advanced welding processes (ISBN ) Many new, or relatively new, welding processes such as friction stir welding, resistance spot welding and laser welding are being increasingly adopted by companies to replace or improve on traditional welding techniques. Improvements in welding speed and ease ofautomation are often used as reasons for choosing advanced welding processes. Before advanced techniques are employed, their potential failure mechanisms should be well understood and their suitability for welding particular metals and alloys in different situations should be assessed. This important book will provide a critical analysis of advanced welding techniques and their potential failure mechanisms. Materials, design and manufacturingfor lightweight vehicles (ISBN ) Research programs into the manufacture of lightweight automobiles have led to the consideration of a variety of materials, such as high strength steels, aluminium alloys, magnesium alloys, plastics and composites. This research is driven by a need to reduce fuel consumption to preserve dwindling hydrocarbon resources without compromising other attributes such as safety, performance, recyclability and cost. This important book will make it easier for engineers to not only learn about the materials being considered for lightweight automobiles, but also to compare their characteristics and properties. It also covers issues such as crashworthiness and recycling. The welding ofaluminium and its alloys TSBN ) welding of aluminium and its alloys is a practical user's guide to all aspects elding aluminium and aluminium alloys, giving a basic understanding of the lurgical principles involved. The book is intended to provide engineers with ps little prior acquaintance with the welding processes involved, a concise and ive reference to the subject. It covers weldability of aluminium alloys, process ptions, advantages, limitations, proposed weld parameters, health and safety preparation for welding, quality assurance and quality control issues. It is tial reading for welding engineers, production engineers, production managers, lers and supervisors involved in the aluminium fabrication industry. Is of these and other Woodhead Publishing materials books can be obtained by: visiting our web site at xmtacting Customer Services ( sales@woodheadpublishing.com; fax: +44 (0) ; tel.: +44 (0) ext. 130; address: Woodhead Publishing Limited, 80 High Street, Sawston, Cambridge CB22 3HJ, UK u would like to receive information on forthcoming titles, please send your address ils to: Francis Dodds (address, telephone and fax as above; francis.dodds dheadpublishing.com). Please confirm which subject areas you are interested in. Woodhead Publishing Limited, 2010

2 Welding and joining of magnesium alloys Edited by Liming Liu WP WOODHEAD PUBLISHING, ^ Oxford Cambridge Philadelphia New Delhi

3 Contents Contributor contact details xi Part I General 1 1 Introduction to the welding and joining of magnesium Background Characteristics of magnesium alloy welded joints under dynamic load Efficient gas metal arc welding of magnesium alloys Dissimilar welding of magnesium alloys to other metals References 7 2 Welding metallurgy of magnesium alloys Introduction Weldability of magnesium alloys Weldability of magnesium alloys to other metals References 14 3 Preparation for welding of magnesium alloys Introduction Surface treatment of magnesium alloys Welding groove for magnesium alloys Preheating and postweld treatments for magnesium alloys References 22 V

4 vi Contents 4 Welding materials for magnesium alloys Introduction Hot extrusion process of welding materials Component design of welding materials Hot pull process of welding materials Microstructure and strength of welding materials References 36 5 Welding and joining of magnesium alloys to aluminum alloys Introduction Hybrid laser-tungsten inert gas welding of magnesium and aluminum Diffusion bonding magnesium to aluminum technology Laser weld bonding magnesium to aluminum technology Conclusion and future trends References 61 6 The joining of magnesium alloy to steel Introduction Existing problems in the joining of magnesium alloys to steel Welding principles for the joining of magnesium alloys to steel Direct joining of magnesium alloys to mild steel Nickel-added joining of magnesium alloys to steel Conclusion and future trends References 77 7 Corrosion and protection of magnesium alloy welds Introduction Corrosion characteristics of magnesium alloy weldment Improvement in the corrosion resistance of magnesium alloy weldment Conclusion and future trends References 93 Woodhead Publishing Limited, 2010

5 Contents vii Part II Particular welding and joining techniques 95 8 Brazing and soldering of magnesium alloys 97 T. Watanabe, Niigata University, Japan 8.1 Surface preparation of magnesium alloys before joining Brazing of magnesium alloys using flux and filler metal Ultrasonic brazing of magnesium alloys with no flux Soldering of magnesium alloys References Mechanical joining of magnesium alloys 122 M. Heger, BOllhoff, Germany and M. Horstmann, Hella KGaA Hueck & Co., Germany 9.1 Introduction Technologies with pre-punching operation and one-sided accessibility Technologies with pre-punching operation and two-sided accessibility Technologies without pre-punching operation and one-sided accessibility Technologies without pre-punching operation and two-sided accessibility Linear technology: hemming References Adhesive bonding of magnesium alloys Introduction Surface treatments of magnesium alloys Adhesive for the bonding of magnesium alloys Cure for the bonding of magnesium alloys Applications of the bonding of magnesium alloys Future trends References Gas-tungsten arc welding of magnesium alloys Introduction Gas-tungsten arc welding of magnesium alloys without filling wire Gas-tungsten arc filler welding of magnesium alloys References 175

6 viii Contents 12 Metal inert gas welding of magnesium alloys 178 G. Song, Dalian University of Technology, China 12.1 Introduction Pulsed metal inert gas welding for magnesium alloys Alternating current metal inert gas welding for magnesium alloys Conclusion and future trends References Variable polarity plasma arc welding of magnesium alloys 197 Z.D. Zhang, Dalian University of Technology, China 13.1 Introduction Variable polarity plasma arc welding of magnesium alloys Variable polarity plasma arc weld bonding of magnesium alloys Conclusion and future trends References Hybrid laser-arc welding of magnesium alloys 229 G. Song, Dalian University of Technology, China 14.1 Introduction Low-power laser/arc hybrid welding of magnesium Hybrid welding process with filler metal Practical application Conclusion and future trends References Activating flux tungsten inert gas welding of magnesium alloys 253 Z.D. Zhang, Dalian University of Technology, China 15.1 Introduction Welding mechanism Welding parameters Microstructure of welding joints Mechanical properties Future trends References Friction stir welding of magnesium alloys 274 H. Zhang, University of Science and Technology, Beijing, China 16.1 Introduction Welding parameters and procedures Welding tools and equipment 280

7 Contents ix 16.4 Materials that have been or are being friction stir welded Typical microstructures of friction stir welded magnesium alloys Properties of friction stir welded magnesium alloys Weld defects of friction stir welded magnesium alloys Applications of friction stir welded magnesium alloys Future trends and sources of further information and advice Acknowledgements References Laser welding of magnesium alloys 306 J. Shan, Tsinghua University, China 17.1 Introduction Character of the laser welding process and influence of laser welding parameters Laser welding of magnesium alloys Microstructure and properties of laser welding of magnesium alloys Typical defects of laser welding of magnesium alloys Outlook and future trends References Resistance spot welding of magnesium alloys 351 L. Liu, University of Waterloo, Canada, J. Feng, Harbin Institute of Technology, China and Y. Zhou, University of Waterloo, Canada 18.1 Introduction Fundamentals of resistance spot welding Welding conditions: surface Welding conditions: welding parameters Nugget growth and microstructure Welding of magnesium alloys to other alloys Equipment for the welding of magnesium alloys Future trends References Electromagnetic pulse welding of magnesium to aluminium sheets 367 S. Kore, Indian Institute of Technology, Guwahati, India and J. Imbert, Y. Zhou and M. Worswick, University of Waterloo, Canada 19.1 Introduction Fundamental theory of electromagnetic welding Equipment for electromagnetic welding Welding technique and materials Mechanical and metallurgical testing of welds 374 Woodhead Publishing Limited, 2010

8 X Contents 19.6 Safety guidelines while handling the electromagnetic welding setup 3J References ins Index 380