Multi-scale characterization and simulation of impact welding between immiscible Mg/steel alloys

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Vaporizing foil actuator spot welding method is used in this paper to join magnesium alloy AZ31 and uncoated high-strength steel DP590,which are typically considered as un-weldable due to their high physical property disparities,low mutual solubility,and the lack of any intermetallic phases.Charac-terization results from scanning electron microscopy (SEM) and high-resolution transmission electron microscopy (HRTEM) of the weld interface indicate that the impact creates an Mg nanocrystalline inter-layer with abundant Fe particles.The interlayer exhibits intact bonding with both DP590 and AZ31 substrates.To investigate the fundamental bond formation mechanisms at the interface,a finite element(FE)-based process simulation is first performed to calculate the local temperature and deformation at the interface under the given macroscopic experimental condition.Taking the FE results at the inter-face as inputs,molecular dynamics (MD) simulations are conducted to study the interlayer formation at the Mg/Fe interface during the impact and cooling.The results found a high velocity shearing-induced mechanical mixing mechanism that mixes Mg/Fe atoms at the interface and creates the interlayer,leading to the metallurgical bond between Mg/steel alloys.
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