Multiphase-field analysis of the intermetallic compounds formation & evolution in friction stir welding of dissimilar Al/Mg alloys

It is essential to understand the formation and evolution mechanism of intermetallic compounds (IMCs) in friction stir welding (FSW) of dissimilar Al/Mg alloys to mitigate the deleterious effect of hard and brittle IMCs on the performance of dissimilar joints. To this end, a multiphase-field model with input variables of both temperature and strain rate is developed to study the whole IMCs formation and growth process at the Al/Mg bonding interface in weld nugget zone. The effects of diffusion, elastic deformation, and large plastic deformation on the generation and growth of IMCs are considered. The numerical simulation results indicate that due to the influence of high dislocation density, the higher diffusion coefficient of the Mg matrix leads to the nucleation of Al12Mg17 first. When IMCs grow into layers, the higher diffusion coefficient of Al3Mg2 leads to a faster growth rate of Al3Mg2 than that of Al12Mg17. The elastic energy caused by lattice mismatch between IMCs and matrix plays an inhibitory role in the growth of IMCs. Large plastic deformation in FSW causes an increase in both the stored energy which promotes the IMCs growth and the dislocation density which intensifies the diffusion process, causing IMCs to form at the interface in a short time. With the model, the IMCs evolution from generation to growth is quantitatively analyzed. The predicted thickness of IMCs matches well with the experimental measurements.