Gas tungsten arc welding of fine-grained AZ31B magnesium alloys made by powder metallurgy

• Arc welding was applied to P/M AZ31B alloys with various oxygen contents.
• Porosity is formed in weld joints of P/M AZ31B alloys with high oxygen contents.
• Porosity originates mainly from the decomposition of Mg hydroxide in base metal.
• Tensile strength of sound weld joints of P/M AZ31B alloys is comparatively high.

AZ31B magnesium alloys with various grain sizes and oxygen contents were prepared by powder metallurgy (P/M) combined with hot extrusion, and the P/M magnesium alloys were subjected to gas tungsten arc welding (GTAW). Porosities are observed in weld joints of the P/M AZ31B alloys with high oxygen contents. Gas composition analysis of porosity shows that the porosity originates mainly from the decomposition of magnesium hydroxide formed during the fabrication of magnesium alloys. The porosity can be decreased or prevented by reducing the amount of magnesium hydroxide (which is expressed as oxygen content in the present study) in the base materials, through controlling the P/M processing time. Use of a filler rod and/or an insert sheet containing rare earth element La tends to decrease the porosity in weld joints. When oxygen content in P/M AZ31B alloys is reduced to 440 ppm or less, sound weld joints without porosity are obtained. Mechanical test demonstrates that tensile strength of the sound weld joints of P/M AZ31B alloys is at the same level as that of weld joint of a commonly hot-extruded AZ31B alloy.