Resistance spot welding of AZ series magnesium alloys: Effects of aluminum content on microstructure and mechanical properties

The microstructural evolution of the spot welded AZ31, AZ61 and AZ80 magnesium alloys was studied via optical and scanning electron microscopy. As the Al content of the magnesium base alloy increased from 3 wt% (AZ31) to 6% (AZ61) and 8% (AZ80), columnar to equi-axed dendrite transition and grain refinement in the fusion zone were enhanced. However, the increasing amount of the β-Mg17(Al,Zn)12 phase in the heat affected zone (HAZ) and fusion zone (FZ) resulted in the reduction of the tensile shear strengths of the AZ61 and AZ80 welds compared to those of AZ31 welds. Moreover, in the tensile-shear testing, the AZ61 and AZ80 welds failed in the heat affected zone along the fusion boundary, because micro-cracking occurred preferentially at the interfaces between β particles and Mg matrix. Post-weld solutionizing treatment was found to significantly reduce the quantity of β particles in heat affected and fusion zones of AZ61 and AZ80 welds. This led to an increase in the weld strengths of AZ61 and AZ80 alloys because the heat treatment eliminated the β particles and cracks propagated into the coarse-grained heat affected zone and then base material. For the heat treated welds, grain size was found as a major factor in the failure mode.