Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment
The formation of brittle intermetallic compounds (IMCs) at the interface during Al–Ni dissimilar joining deteriorates joint strength, thereby limiting their applicability in high-performance engineering structures. This study investigates the effects of a high-entropy alloy (HEA) interlayer, CoCrFeM...
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| Format: | Article |
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Elsevier
2025-09-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425018903 |
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| author | Byoungwook Choi Yoona Lee Seonghoon Yoo Bong Cheon Park Junggwan An Jason Cheon Dong-Yun Lee Sung-Dae Kim Wookjin Lee Yoon Suk Choi Namhyun Kang |
| author_facet | Byoungwook Choi Yoona Lee Seonghoon Yoo Bong Cheon Park Junggwan An Jason Cheon Dong-Yun Lee Sung-Dae Kim Wookjin Lee Yoon Suk Choi Namhyun Kang |
| author_sort | Byoungwook Choi |
| collection | DOAJ |
| description | The formation of brittle intermetallic compounds (IMCs) at the interface during Al–Ni dissimilar joining deteriorates joint strength, thereby limiting their applicability in high-performance engineering structures. This study investigates the effects of a high-entropy alloy (HEA) interlayer, CoCrFeMnNi, and post weld heat treatment (PWHT) on the interfacial microstructure and mechanical performance in dissimilar Al–Ni friction stir lap welding (FSLW). Without the interlayer, a brittle Al3Ni IMC layer formed at the interface and grew significantly after PWHT, leading to interfacial fracture and reduced joint efficiency (∼20 %). In contrast, the application of an HEA interlayer suppressed IMC formation and led to the formation of a nanoscale amorphous layer under as-welded conditions, which effectively prevented interfacial fracture and enhanced joint efficiency (∼63 %). After PWHT, a favourable Al13M4 IMC layer formed, wherein the M-site was co-occupied by Co, Cr, Fe, Mn, and Ni. This IMC exhibited no brittleness and effectively prevented interfacial fracture. Moreover, superior joint strength was achieved after PWHT which promoted the re-precipitation of strengthening precipitates that had previously been dissolved during FSLW owing to thermal exposure of the Al matrix. Joint efficiency thus improved to ∼93 % which is comparable to the base metal. The synergistic combination of an HEA interlayer and PWHT is a promising strategy for suppressing the formation and growth of brittle IMCs and for enhancing the reliability of dissimilar Al–Ni joints. |
| format | Article |
| id | doaj-art-043abda876de403ab938fe3511b7c6f7 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-043abda876de403ab938fe3511b7c6f72025-08-20T03:59:40ZengElsevierJournal of Materials Research and Technology2238-78542025-09-01381342135410.1016/j.jmrt.2025.07.232Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatmentByoungwook Choi0Yoona Lee1Seonghoon Yoo2Bong Cheon Park3Junggwan An4Jason Cheon5Dong-Yun Lee6Sung-Dae Kim7Wookjin Lee8Yoon Suk Choi9Namhyun Kang10Department of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of KoreaDepartment of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of KoreaDepartment of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of KoreaDepartment of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of Korea; Materials Data & Analysis Research Division, Korea Institute of Materials Science, Changwon, 51508, Republic of KoreaFlexible Manufacturing R&D Department, Korea Institute of Industrial Technology, Incheon, 21999, Republic of KoreaFlexible Manufacturing R&D Department, Korea Institute of Industrial Technology, Incheon, 21999, Republic of KoreaDepartment of Aluminum, Advanced Metals Divisions, Korea Institute of Materials Science, Changwon, 51508, Republic of KoreaDepartment of Materials Science and Engineering, Pukyong National University, Busan, 48513, Republic of KoreaDepartment of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of Korea; Institute of Materials Technology, Pusan National University, Busan 46241, Republic of KoreaDepartment of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of Korea; Institute of Materials Technology, Pusan National University, Busan 46241, Republic of KoreaDepartment of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of Korea; Institute of Materials Technology, Pusan National University, Busan 46241, Republic of Korea; Corresponding author. Institute of Materials Technology, Pusan National University, Busan 46241, Republic of Korea.The formation of brittle intermetallic compounds (IMCs) at the interface during Al–Ni dissimilar joining deteriorates joint strength, thereby limiting their applicability in high-performance engineering structures. This study investigates the effects of a high-entropy alloy (HEA) interlayer, CoCrFeMnNi, and post weld heat treatment (PWHT) on the interfacial microstructure and mechanical performance in dissimilar Al–Ni friction stir lap welding (FSLW). Without the interlayer, a brittle Al3Ni IMC layer formed at the interface and grew significantly after PWHT, leading to interfacial fracture and reduced joint efficiency (∼20 %). In contrast, the application of an HEA interlayer suppressed IMC formation and led to the formation of a nanoscale amorphous layer under as-welded conditions, which effectively prevented interfacial fracture and enhanced joint efficiency (∼63 %). After PWHT, a favourable Al13M4 IMC layer formed, wherein the M-site was co-occupied by Co, Cr, Fe, Mn, and Ni. This IMC exhibited no brittleness and effectively prevented interfacial fracture. Moreover, superior joint strength was achieved after PWHT which promoted the re-precipitation of strengthening precipitates that had previously been dissolved during FSLW owing to thermal exposure of the Al matrix. Joint efficiency thus improved to ∼93 % which is comparable to the base metal. The synergistic combination of an HEA interlayer and PWHT is a promising strategy for suppressing the formation and growth of brittle IMCs and for enhancing the reliability of dissimilar Al–Ni joints.http://www.sciencedirect.com/science/article/pii/S2238785425018903Dissimilar joiningFriction stir lap weldingHigh-entropy alloyInterlayerIntermetallic compounds |
| spellingShingle | Byoungwook Choi Yoona Lee Seonghoon Yoo Bong Cheon Park Junggwan An Jason Cheon Dong-Yun Lee Sung-Dae Kim Wookjin Lee Yoon Suk Choi Namhyun Kang Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment Journal of Materials Research and Technology Dissimilar joining Friction stir lap welding High-entropy alloy Interlayer Intermetallic compounds |
| title | Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment |
| title_full | Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment |
| title_fullStr | Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment |
| title_full_unstemmed | Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment |
| title_short | Achievement of superior strength in Al–Ni dissimilar joints through designing high-entropy alloy interlayer and post weld heat treatment |
| title_sort | achievement of superior strength in al ni dissimilar joints through designing high entropy alloy interlayer and post weld heat treatment |
| topic | Dissimilar joining Friction stir lap welding High-entropy alloy Interlayer Intermetallic compounds |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425018903 |
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