Joining mechanism, microstructure, and mechanical properties of AZ31/6061 joint prepared by pouring fusion welding process assisted with Zn-xSn brazing filler

In this study, AZ31/6061 dissimilar metal joints were manufactured using pouring fusion welding assisted with Zn-xSn brazing filler, and the process, microstructure and mechanical properties of Mg/Al joint were investigated. During welding, the addition of molten Zn-xSn brazing filler completely isolates the direct contact of Mg/Al, preventing the formation of Mg-Al intermetallic compounds. As the Sn content changes, the microstructure of the joints also changes. When the Sn content is 25 wt.%, the microstructure of the AZ31 side is dominated by Mg-Al-Zn ternary eutectic structure, Al6Mg11Zn11, (& beta;-Zn + MgZn2), Al-Zn-Sn (SS), Sn (SS) and Mg2Sn. And the microstructure of the 6061 side is dominated by Al-Zn-Sn (SS), & beta;-Zn, Al-Zn-Sn (SS), and Sn (SS). The width of the Mg-Al-Zn ternary eutectic structure layer decreases with the increase of Sn content. In addition, high Sn content and high heat input promote the formation of Mg2Sn, and large amounts of Mg2Sn are generated with Zn-40Sn interlayer. The average microhardness of the joint gradually decreases with the increase of Sn content. However, the shear strength of the joint first increases and then decreases, and the shear strength of the joint with the Zn-25Sn interlayer is the highest, which is 50.60 MPa. Fracture mode is cleavage fracture.