Ultrasonic welding of AZ31B magnesium alloy

This article overviews the ultrasonic welding process, a solid-state joining method, using the example of welding of a magnesium alloy as well as the joining of magnesium alloys in general. In situ high-speed imaging and infrared thermography were utilized to study interfacial relative motion and heat generation during ultrasonic spot welding of AZ31B magnesium (Mg) alloys. A postweld ultrasonic nondestructive evaluation was performed to study the evolution of local bond formation at the faying interface (contact surface of the joint between the top and bottom Mg sheets) at different stages of the welding process. Two distinct stages were observed as the welding process progresses. In the early stage, localized reciprocating sliding occurred at the contact faying interface between the two Mg sheets, resulting in localized rapid temperature rise from the localized frictional heating. Microscale (submillimeter) bonded regions at the Mg-Mg faying surface started to form, but the overall joint strength was low. The early-stage localized bonds were broken during the subsequent vibrations. In the later stage, no relative motion occurred at any points of the faying interface. Localized bonded regions coalesced into a macroscale joint that was strong enough to prevent the Mg-Mg interface from further breakage and sliding. With increasing welding time, the bonded area continued to increase.