Advancements in joining Al-Zn-TiC-Mg composites using friction stir welding process: Influence of traverse speed

In this article, dissimilar magnesium and aluminum alloys were welded with a Zn interlayer and TiC nanoparticles by friction stir welding. Optimal joining conditions were achieved by a combination of three traverse speeds (30, 45, and 60 mm/min) and constant rotational speeds (1050 rpm). The best microstructure evolution and mechanical properties were achieved for specimens joined at rotational and traverse speeds of 1050 rpm and 45 mm/min, respectively. The grain size decreases as the traverse speed increases from 30 to 45 mm/min due to a reduction in heat input, an improvement in reinforcing distribution, and high intermixing of materials, then increases from 45 to 60 mm/min due to inadequate heat input for recrystallization process. It was shown that the TiC particles play a prominent role in the microstructure modification and enhance mechanical properties of weld samples while the Zn foil interlayer plays a vital in avoiding the formation of Al-Mg IMC phases. The obtained result under optimal welding parameters indicates that MgZn2, Mg-Al-Zn compounds, Mg and Al solid solution, were the main detected common phases in the stir zone instead of the brittle and hard Al-Mg IMCs formation. The average hardness values of 232 Hv were achieved, while the strength of the weld specimen experiences the 189 MPa value. In addition, a combination of brittle and ductile modes was observed based on the fracture surface of the weld sample after the tensile test.