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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,711 records · Page 95
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Methodology for Thermodynamic Analysis Coupled with Computational Fluid Dynamics Modeling for Casting a Novel Aluminum–Cerium Alloy

In this paper, we present the results of computational fluid dynamics (CFD) analysis to assess castability, porosity, molten metal fluidity and other technological properties of a new Al-Ce alloy. A thermodynamic analysis of a new Al-Ce alloy is done to obtain the physical properties as a function of temperature across both solid and liquid phases. These properties are then used to build the CFD of model the full casting process from initial pouring through to final solidification of the part, here an example of a heavy duty mor mount is used. While several excellent commercial CFD codes exists this process shows that CFD can be used to assess the capability of the alloy to properly fill the mold, as well as give predictions where scattered porosity or large-scale defects may occur in the casting. Further, unlike the commercially available software (e.g., ProCAST, SOLIDCast , MAGMASOFT®) the complex 3D-analysis of the stress / strain fields in cast parts is not performed at this time. However, the availability of free software for assessing the required thermodynamic / thermo-physical properties of new alloys (OpenCALPHAD) and CFD codes such as OpenFOAM® makes the developed option attractive and economical, especially for the analysis of new Al-Ce alloys, for which the available data does not exist.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Characterization of dislocation structures and deformation mechanisms in as-grown and deformed directionally solidified NiAl–Mo composites

In this paper, directionally solidified (DS) NiAl–Mo eutectic composites were strained to plastic strain values ranging from 0% to 12% to investigate the origin of the previously observed stochastic versus deterministic mechanical behaviors of Mo-alloy micropillars in terms of the development of dislocation structures at different pre-strain levels. The DS composites consist of long, [1 0 0] single-crystal Mo-alloy fibers with approximately square cross-sections embedded in a [1 0 0] single-crystal NiAl matrix. Scanning transmission electron microscopy (STEM) and computational stress state analysis were conducted for the current study. STEM of the as-grown samples (without pre-straining) reveal no dislocations in the investigated Mo-alloy fibers. In the NiAl matrix, on the other hand, a(1 0 0)-type dislocations exist in two orthogonal orientations: along the [1 0 0] Mo fiber axis, and wrapped around the fiber axis. They presumably form to accommodate the different thermal contractions of the two phases during cool down after eutectic solidification. At intermediate pre-strain levels (4–8%), a/2(1 1 1)-type dislocations are present in the Mo-alloy fibers and the pre-existing dislocations in the NiAl matrix seem to be swept toward the interphase boundary. Some of the dislocations in the Mo-alloy fibers appear to be transformed from a(1 0 0)-type dislocations present in the NiAl matrix. Subsequently, the transformed dislocations in the fibers propagate through the NiAl matrix as a(1 1 1) dislocations and aid in initiating additional slip bands in adjacent fibers. Thereafter, co-deformation presumably occurs by (1 1 1) slip in both phases. With a further increase in the pre-strain level (>10%), multiple a/2(1 1 1)-type dislocations are observed in many locations in the Mo-alloy fibers. Interactions between these systems upon subsequent deformation could lead to stable junctions and persistent dislocation sources. Finally, the transition from stochastic to deterministic, bulk-like behavior in sub-micron Mo-alloy pillars may therefore be related to an increasing number of multiple a(1 1 1) dislocation systems within the Mo fibers with increasing pre-strain, considering that the bulk-like behavior is governed by the forest hardening of these junctions.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Structure-processing correlations and mechanical properties in freeze-cast Ti-6Al-4V with highly aligned porosity and a lightweight Ti-6Al-4V-PMMA composite with excellent energy absorption capability

In contrast to freeze-cast ceramics and polymers, few freeze-cast metals have been described, to date. This systematic study on structure-processing correlations in freeze-cast Ti-6Al-4V scaffolds reports how processing parameters determine the architecture formed during the directional solidification of water-based metal slurries and after sintering. Additionally, sedimentation in the slurry during freezing and volume shrinkage during burnout and sintering were found to significantly affect both structure and properties of the scaffolds. In using two freezing rates, 1 and 10 °C min -1 , two water-based polymer solutions as binders (chitosan and carboxymethyl cellulose) and two different metal volume fractions in the slurry, 20 and 30 vol%, Ti-6Al-4V scaffolds could be prepared with pore length, width, and porosity ranging from 41 to 523 μm, 14.5–76.5 μm, and 65 to 34%, respectively. Their compressive strength, stiffness, and toughness (work to 20% strain) fall in the range of 83–412 MPa, 7–29 GPa, and 14–122 MJ m -3 , respectively. In order to improve the properties a select composition was infiltrated with poly(methyl methacrylate). This increased the average yield strength by a factor of 2.3 from 83 to 193 MPa and the average toughness (work to 50% strain) by a factor of 2.7 from 28.1 to 76.8 MJ m -3 .

36 MATERIALS SCIENCE↗
DOE OSTI2025

Assessment of critical flaw sizes and crack driving forces during additive manufacturing of metallic materials

Additive manufacturing (AM) of complex engineering components is often plagued by a high susceptibility to cracking, particularly in high-strength metallic materials. While alloy design efforts have made progress in mitigating solidification defects, there remains a need for mechanistic guidelines to predict susceptibility to solid-state cracking. To address this gap, driving forces for the growth of melt pool cracks are calculated across a wide range of alloys using an efficient computational framework. Calculations are coupled with rapid single track laser experiments to elucidate trends in cracking from laser melting. The analyses conducted here highlight the important role of material properties in susceptibility to cracking, notably fracture toughness and elastic modulus. An important finding is that residual stresses that are limited in magnitude to the yield stress of the material are likely insufficient to drive cracking during cooling. Furthermore, the implications of these results are discussed in the context of alloy design for AM and residual stress accumulation during AM.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Which way does the dendrite grow? Competition among epitaxy, preferred growth direction, and thermal gradients in powder bed fusion additive manufacturing

The as-processed microstructure of metal alloy parts manufactured through laser powder bed fusion (LPBF) is heavily derived from the cellular dendritic solidification. The growth direction of dendrites within the melt pool is determined through competition among epitaxial growth, preferred growth directions, and maximum thermal gradients. However, the dominant factor and the specific role of each in developing melt pool microstructures remain unknown. Here, in this study, we performed single laser track scans on an SS316L single crystal substrate and combined experimental characterization of microstructure and crystal orientations with Computational Fluid Dynamics simulations of thermal gradients to evaluate the role of each factor in determining dendritic growth direction and evolution. Our results reveal that epitaxial growth dominates microstructure development by preferentially growing along a single 〈100〉 variant of the single crystal substrate adjacent to the melt pool boundary. Under LPBF’s highly curved and rapidly evolving thermal field, this preferential dendrite variant selection and its continued growth from the melt pool boundary to the centerline are governed by the local temperature gradient magnitude at the solid-liquid interface, rather than by the instantaneous maximum temperature gradient direction alone. Using these findings, we successfully predict changes in the dendrite growth direction with changing laser scan direction on a single crystal substrate, and show that the geometric melt pool centerline can deviate from the microstructural centerline because asymmetric local temperature gradient magnitudes transiently limit growth, resulting in different dendrite travel distances on each side of the melt pool.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Reduction of water content in calcium aluminate cement with/out phosphate modification for alternative cementation technique

Cementation of the secondary aqueous wastes from TEPCO Fukushima Daiichi Nuclear Power Plant is challenging due to the significant strontium content and radioactivity, leading to a potential risk of hydrogen gas generation via radiolysis of water content. The present study investigates the reduction of water content in calcium aluminate cement (CAC) with/out phosphate modification by a heat-treatment during the solidification. The reduction of water in the CAC was found restricted by the rapid formation of crystalline hydration phases, whereas the phosphate-modified system allowed the gradual reduction of water, achieving the reduction of 60% water content at 95 °C. Curing at 60–95 °C also eliminated the significant cracks found at 35 °C in the phosphate system. The possible difference in the amorphous products, NaCaPO{sub 4}·nH{sub 2}O type at 35°C and Ca(HPO{sub 4})·xH{sub 2}O type at 60–95 °C, may have contributed to the improvement in the microstructure together with the change in the pore size distribution.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Ordering in liquid and its heredity impact on phase transformation of Mg-Al-Ca alloys

It is a long-sought goal to achieve desired mechanical properties through tailoring phase formation in alloys, especially for complicated multi-phase alloys. In fact, unveiling nucleation of competitive crystalline phases during solidification hinges on the nature of liquid. Here we employ ab initio molecular dynamics simulations (AIMD) to reveal liquid configuration of the Mg-Al-Ca alloys and explore its effect on the transformation of Ca-containing Laves phase from Al 2 Ca to Mg 2 Ca with increasing Ca/Al ratio (r Ca/Al ). There is structural similarity between liquid and crystalline phase in terms of the local arrangement environment, and the connection schemes of polyhedras. The forming signature of Mg 2 Ca, as hinted by the topological and chemical short-range order originating from liquid, ascends monotonically with increasing r Ca/Al . However, Al 2 Ca crystal-like order increase at first and then decrease at the crossover of r Ca/Al = 0.74, corresponding to experimental composition of phase transition from Al 2 Ca to Mg 2 Ca. The origin of phase transformation across different compositions lies in the dense packing of atomic configurations and preferential bonding of chemical species in both liquid and solid. The present finding provides a feasible scenario for manipulating phase formation to achieve high performance alloys by tailoring the crystal-like order in liquid.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microstructural banding of directed energy deposition-additively manufactured 316L stainless steel

The microstructures of 316 L stainless steel created by rapid solidification are investigated here by comparing the similar microstructures of individual hatches of directed energy deposition additive manufacturing (DED-AM) and those of single, laser surface-melted tracks formed on a solid plate. High recoil pressure, which is exponentially dependent on the laser beam power density, induces convection of the melt pool, which causes formation of microstructural bands in the as-solidified microstructure. The microstructural bands are associated with changes in the chromium concentration and are a significant component of the inhomogeneous microstructure of DED-AM.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Heavy ion irradiation response of an additively manufactured 316LN stainless steel

Additive manufacturing has become an appealing technique to fabricate three-dimensional metallic materials and components for nuclear reactors. However, response of additively manufactured alloys to high-dose heavy ion irradiations at elevated temperatures is still not well understood. Here, an additively manufactured 316LN austenitic stainless steel with high-density solidification cells was irradiated using 3.5 MeV Fe ion to a peak dose of 220 dpa at 450 °C. Microscopy studies show a lower Frank loop density and smaller size in the additively manufactured sample compared with its cold worked counterpart, and the cellular structures may largely suppress the formation of perfect loops and dislocation networks and reduce the magnitude of solute segregations comparing with high angle grain boundaries. In conclusion, the present work advances the understanding on the high-temperature irradiation response of additively manufactured steels for nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Microstructure, mechanical properties and texture evolution of AZ31 alloy containing trace levels of strontium

The effect of low levels of Sr (0.01, 0.03, 0.05 wt.%) on the microstructure, mechanical properties and texture of AZ31 magnesium alloy has been investigated. Thermodynamic modeling has been used to study the effect of Sr on phase precipitation at different temperatures. Cooling curve analysis reveals a decrease in solidification superheat with the addition of 0.03 wt.% Sr to AZ31. The as-cast microstructures of the alloys have been studied using optical microscopy (OM) and electron probe micro analysis (EPMA). Results show the refining effect of Sr on the grain size and on the {beta}-Mg{sub 17}Al{sub 12} precipitates through growth poisoning and inoculation, respectively. To investigate the mechanical properties of the alloys, as-cast samples were compression tested at elevated temperatures. Hot compression peak stress ({sigma}{sub max}) and critical strain before recrystallization ({epsilon}{sub c}) initially drop but then increase. {sigma}{sub max} first decreases due to the depletion of Al from solid solution and then increases when the amount of the Al-Sr precipitates reach a significant amount. {epsilon}{sub c} drops due to the acceleration of dynamic recrystallization kinetics as a result of grain refinement. It increases with increasing Sr when the concentration Sr in solid solution is increased leading to dislocation pinning and retardation of recrystallization. X-ray texture measurements on the hot compressed and extruded samples show a decrease in maximum intensity of the basal pole figures with increasing Sr as a result of reduced twining and the changes in Al and Sr concentrations in solid solution. - Research Highlights: {yields} Microstructures/precipitates of AZ31+trace levels of Sr were examined by OM and EPMA. {yields} Thermodynamic calculations and cooling curve analysis were used to predict ppt formation. {yields} It has been shown that Sr refines the grains and Mg17Al12 precipitates. {yields} Mechanical properties and texture were studied using hot compression and X-ray diffraction. {yields} Different micro-mechanisms were responsible for mechanical and texture changes.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Experimental and calculated phases in two as-cast and annealed Mg-Zn-Y alloys

The CALPHAD (Calculation of Phase Diagram) method was used to select ternary alloys from Mg-Zn-Y system, aimed at determining the role of precipitates in the microstructure and texture evolution of Mg during and after deformation. The selected alloys are Mg-6Zn-1.2Y and Mg-5Zn-2Y. The constituent phases in the as-cast Mg-6Zn-1.2Y alloy are {alpha}-Mg solid solution phase and I (Mg{sub 3}YZn{sub 6}) intermetallic phase. The as-cast Mg-5Zn-2Y alloy is composed of {alpha}-Mg, I and W (Mg{sub 3}Y{sub 2}Zn{sub 3}) phases. The intermetallics in the two alloys form by eutectic reaction, which in Mg-5Zn-2Y alloy results in initially W-phase formation and ultimately I-phase formation during solidification. After heat treatment, the Mg-6Zn-1.2Y and Mg-5Zn-2Y alloys contain nearly the same amount of ternary intermetallics (I and W phases, respectively) in equilibrium with {alpha}-Mg solid solution phase. The main solute in {alpha}-Mg phase is Zn with the same amount in the two alloys. The type and quantity of the phases obtained experimentally disagree with the results obtained from the thermodynamic database. One important discrepancy is that, in Mg-6Zn-1.2Y alloy, the I phase is not stable at the temperature of 430 Degree-Sign C, and that the W phase is the stable phase at this temperature. The differences in the experimental and calculated data indicate that the Mg-Zn-Y system requires to be reassessed with more experimental data. - Highlights: Black-Right-Pointing-Pointer Mg-6Zn-1.2Y and Mg-5Zn-2Y alloys were selected by FactSage Trade-Mark-Sign Thermodynamic software. Black-Right-Pointing-Pointer The I and W intermetallics in the two alloys form by eutectic reaction. Black-Right-Pointing-Pointer The alloys contain similar amounts of different intermetallics in equilibrium with {alpha}-Mg. Black-Right-Pointing-Pointer In Mg-6Zn-1.2Y, the I phase is not stable at the temperature of 430 Degree-Sign C. Black-Right-Pointing-Pointer The hardness of W phase is determined to be lower than that of I phase.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Evaluation of microstructural development in electron beam melted Ti-6Al-4V

In the current work an investigation of the microstructures of EBM built Ti-6Al-4V test bars has been performed using OM, SEM, TEM and XRD. It has been found that the prior {beta} phase, that formed during the initial solidification, possesses a column shaped morphology with growing direction parallel to built direction. Typical ({alpha} + {beta}) structures namely Widmanstaetten {alpha} platelets with rod-like {beta} phase formed on the interfaces of the fine {alpha} grains, have been observed in the columnar prior {beta} grains. Grain boundary {alpha} phase was found to be formed around the boundaries of the columnar prior {beta} grains. Different phases present in the parts, especially the BCC {beta} phases have been characterized. The TEM/EDX results indicate very high V composition in the {beta} phase. Results of TEM/SAED and XRD also revealed that a superlattice structure could be present in the {beta} phase. Phase transformation sequence is discussed according to the processing history and the microstructures observed. - Highlights: Black-Right-Pointing-Pointer {alpha} + {beta} and individual {beta} phase is observed and characterized by SEM, TEM and XRD. Black-Right-Pointing-Pointer {beta}-phase is identified as rod-like structure embedded in {alpha} matrix and platelets. Black-Right-Pointing-Pointer Phase transformation sequence is discussed as per thermal history and microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Thermal evolution behavior of carbides and {gamma} Prime precipitates in FGH96 superalloy powder

The characteristics of rapidly solidified FGH96 superalloy powder and the thermal evolution behavior of carbides and {gamma} Prime precipitates within powder particles were investigated. It was observed that the reduction of powder size and the increase of cooling rate had transformed the solidification morphologies of atomized powder from dendrite in major to cellular structure. The secondary dendritic spacing was measured to be 1.02-2.55 {mu}m and the corresponding cooling rates were estimated to be in the range of 1.4 Multiplication-Sign 10{sup 4}-4.7 Multiplication-Sign 10{sup 5} K{center_dot}s{sup -1}. An increase in the annealing temperature had rendered the phase transformation of carbides evolving from non-equilibrium MC Prime carbides to intermediate transition stage of M{sub 23}C{sub 6} carbides, and finally to thermodynamically stable MC carbides. The superfine {gamma} Prime precipitates were formed at the dendritic boundaries of rapidly solidified superalloy powder. The coalescence, growth, and homogenization of {gamma}' precipitates occurred with increasing annealing temperature. With decreasing cooling rate from 650 Degree-Sign C{center_dot}K{sup -1} to 5 Degree-Sign C{center_dot}K{sup -1}, the morphological development of {gamma} Prime precipitates had been shown to proceed from spheroidal to cuboidal and finally to solid state dendrites. Meanwhile, a shift had been observed from dendritic morphology to recrystallized structure between 900 Degree-Sign C and 1050 Degree-Sign C. Moreover, accelerated evolution of carbides and {gamma}' precipitates had been facilitated by the formation of new grain boundaries which provide fast diffusion path for atomic elements. - Highlights: Black-Right-Pointing-Pointer Microstructural characteristic of FGH96 superalloy powder was investigated. Black-Right-Pointing-Pointer The relation between microstructure, particle size, and cooling rate was studied. Black-Right-Pointing-Pointer Thermal evolution behavior of {gamma} Prime and carbides in loose FGH96 powder was studied.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Friction surfaced Stellite6 coatings

Solid state Stellite6 coatings were deposited on steel substrate by friction surfacing and compared with Stellite6 cast rod and coatings deposited by gas tungsten arc and plasma transferred arc welding processes. Friction surfaced coatings exhibited finer and uniformly distributed carbides and were characterized by the absence of solidification structure and compositional homogeneity compared to cast rod, gas tungsten arc and plasma transferred coatings. Friction surfaced coating showed relatively higher hardness. X-ray diffraction of samples showed only face centered cubic Co peaks while cold worked coating showed hexagonally close packed Co also. - Highlights: Black-Right-Pointing-Pointer Stellite6 used as coating material for friction surfacing. Black-Right-Pointing-Pointer Friction surfaced (FS) coatings compared with casting, GTA and PTA processes. Black-Right-Pointing-Pointer Finer and uniformly distributed carbides in friction surfaced coatings. Black-Right-Pointing-Pointer Absence of melting results compositional homogeneity in FS Stellite6 coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2013

The problem of intermixing of metals possessing no mutual solubility upon explosion welding (Cu-Ta, Fe-Ag, Al-Ta)

On the basis of the results obtained for joints of dissimilar metals such as copper-tantalum and iron-silver, the reason of immiscible suspensions mixing upon explosion welding has been cleared out. It has been found that the interface (plain or wavy) is not smooth and contains inhomogeneities, namely, cusps and local melting zones. The role of granulating fragmentation providing partitioning of initial materials as a main channel of input energy dissipation has been revealed. It has been shown that in joints of metals possessing normal solubility the local melting zones are true solutions, but if metals possess no mutual solubility the local melting zones are colloidal solutions. Realization of either emulsion or suspension variant takes place. The results can be used in the development of new joints of metals possessing no mutual solubility. - Highlights: Black-Right-Pointing-Pointer Immiscible pairs Ta/Cu and Fe/Ag are welded successfully by explosive welding. Black-Right-Pointing-Pointer Fragmentation provides for partitioning as the main energy dissipation channel. Black-Right-Pointing-Pointer Immiscible metals form colloidal solid solutions during solidification. Black-Right-Pointing-Pointer Melting and boiling temperatures ratio determines the colloidal solution type. Black-Right-Pointing-Pointer Local melting zones being in suspension form enhance welds hardening.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Shape memory properties and microstructural evolution of rapidly solidified CuAlBe alloys

In this work, the effects of Be addition on the microstructure and phase transformation temperatures of Cu–12Al–xBe (x = 0.4, 0.5 and 0.6 wt.%) shape memory alloys fabricated by using the arc-melting and melt-spinning techniques have been investigated. X-ray diffraction analysis revealed that the arc-melted alloys consisted of austenitic β{sub 1}, martensitic β{sub 1}′ and γ{sub 2} precipitate phases, whereas melt-spun ribbons were composed of a fully martensitic phase. The average grain size of martensitic phases in melt-spun ribbons was determined by electron microscopy images, showing a decrease with increasing Beryllium (Be) amount. Moreover, it was found that the Be addition in the arc-melted alloys had a distinct effect on the morphology of the γ{sub 2} precipitate phase. Transmission electron microscopy analysis showed that the thickness of martensitic plates in the melt-spun ribbons reduced with increasing Be addition. In a differential scanning calorimeter analysis, no martensitic transformation (M{sub s}) peak was observed in arc-melted alloys, but it was clearly detected in melt-spun ribbons, in which M{sub s} decreased dramatically with increasing Be addition. The improvement in the shape memory ability of melt-spun ribbons was explained in terms of the refinement in grain size and martensitic plates. - Highlights: • The CuAlBe SMAs were produced by means of arc-melter and melt-spinner techniques. • MT was directly obtained in melt-spuns without any intermediate process. • The transformation temperatures decreased with increasing Be amount. • The thickness of martensitic plates in the ribbons reduced with increasing Be. • SMP of CuAl was improved by the addition of Be together with rapid solidification.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Microstructure, microstructural stability and mechanical properties of sand-cast Mg–4Al–4RE alloy

This paper presents a methodology for assessing the phase composition and the results of structural stability tests of the sand-cast Mg–4Al–4RE alloy after annealing it at 175 and 250 °C for 3000 h. The microstructure was analyzed with optical, scanning electron, and transmission electron microscopy. The phase composition was determined with X-ray diffraction. The structure of the Mg–4Al–4RE (AE44) alloy is composed of large grains of α-Mg solid solution, needle-shaped precipitates of the Al{sub 11}RE{sub 3}phase, polyhedral precipitates of the Al{sub 2}RE phase and Al{sub 10}RE{sub 2}Mn{sub 7} phase. After annealing at 175 °C for 3000 h, no changes in the alloy structure are observed, whereas after annealing at 250 °C the precipitates of the Al{sub 11}RE{sub 3} phase are found to be in the initial stages of spheroidization. The coarse-grained structure and unfavorable morphology of the intermetallic phases in the sand-cast AE44 alloy, which are caused by low solidification rates, result in low creep resistance up to 200 °C and low mechanical properties at ambient temperature and at 175 °C. - Highlights: • Complement the knowledge about the microstructure of Mg-Al-RE alloys. • Clarify the mechanism of formation of Mg17Al12 phase above 180 °C. • Applying a chemical dissolution of the α-Mg in order to phase identification. • Applying a statistical test to assess the spheroidization of precipitates. • Quantitative description of microstructure of Mg-Al-RE alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Characterization of Mg/Al butt joints welded by gas tungsten arc filling with Zn–29.5Al–0.5Ti filler metal

The multivariate alloying design of a welding joint is used in the Mg to Al welding process. A Zn–29.5Al–0.5Ti alloy is added as filler metal in gas tungsten arc welding of Mg and Al alloy joint based on the analysis of Al and Mg alloy characteristics. The tensile strength, microstructure, and phase constitution of the weld seam are analyzed. The formation of brittle and hard Mg–Al intermetallic compounds is avoided because of the effects of Zn, Al, and Ti. The average tensile strength of the joint is 148 MPa. Al{sub 3}Ti is first precipitated and functions as the nucleus of heterogeneous nucleation during solidification. Moreover, the precipitated Al–MgZn{sub 2} hypoeutectic phase exhibited a feather-like structure, which enhances the property of the Mg–Al dissimilar joint. - Highlights: • Mg alloy AZ31B and Al alloy 6061 are butt welded by fusion welding. • The effect of Ti in filler metal is investigated. • The formation of Mg–Al intermetallic compounds is avoided.

36 MATERIALS SCIENCE↗