因應全球節能減碳趨勢，汽車輕量化技術成為減少碳排重要策略。鋁合金與鎂合金具有重量輕與機械強度高特性，成為理想輕量化材料，被廣泛運用在車輛結構。而異材質接合仍面臨技術挑戰，Al/Mg異材質銲接過程中，Al-Mg脆性金屬間化合物(Intermetallic Compound, IMC)過度生成會降機接合處強度與破斷延伸率。對於不同銲接技術與製程評估，採用固態銲接製程摩擦攪拌銲接(Friction Stir Welding, FSW)作為Al/Mg異材質銲接，探討製程參數對於Al-Mg IMC生成與接合處品質影響。
透過田口式方法(Taguchi Method)L9正交表，調控FSW的關鍵製程參數，包括主軸轉速、銲接速率、肩部下壓量與工具偏移量，以找出擁有最優秀拉伸性質的最佳參數。對於不同參數進行熱輸入的計算，進一步透過微觀結構、機械性質與腐蝕可靠度比較不同熱輸入條件下其中的變化。
微觀結構方面，先透過Pandat模擬接合區內會出現Al-Mg IMC，藉由XRD初步確認接合處內出現的Al-Mg IMC類別為Al3Mg2與Al12Mg17。其中攪拌區(Stir Zone, SZ)內生成之Al-Mg IMC主要是透過擴散反應與共晶反應生成，擴散反應所生成之Al3Mg2與Al12Mg17皆呈現緻密條狀，共晶反應所生成之Al12Mg17呈現分散顆粒狀分布於富Mg相上。熱輸入增加會使攪拌區(SZ)中Al-Mg IMC厚度增加。適配熱輸入使帶狀區(Bond Zone, BZ)中富Al相呈現粗大且連續形貌。攪拌區(SZ)受劇烈塑變，動態再結晶(Dynamic Recrystallization, DRX)發生，晶粒細化，小角度晶界(Low Angle Grain Boundary, LAGB)轉為大角度晶界(High Angle Grain Boundary, HAGB)，多數晶粒為再結晶狀態，形成隨機分布等向性織構，熱輸入增加細化後晶粒成長且再提升再結晶比例。Mg側熱機影響區(Thermo-Mechanically Affected Zone, TMAZ)應變速率較低，動態再結晶驅動力小，晶粒細化效果有限，小角度晶界(LAGB)未能轉變，殘留應力未能釋放，形成擇優取向非等向性織構，熱輸入增加降低材料流動速率，動態再結晶(DRX)驅動力更低，更多殘留應力保留於組織中。
機械性質方面，帶狀區(BZ)中連續性高富Al相有利拉伸塑變均勻，提高抗拉強度。拉伸過程加劇Mg側熱機影響區(TMAZ)應力集中，加上攪拌區(SZ)呈現等向性織構與晶粒細小均勻，Mg側熱機影響區(TMAZ) 呈現非等向性織構與晶粒較粗，造成拉伸過程變形不協調，更進一步使拉伸斷裂路徑出現於攪拌區(SZ)與Mg側熱機影響區(TMAZ)交界區域。共晶反應生成分散顆粒狀Al12Mg17+Mg結構較為鬆散，造成破斷路徑擴展，使拉伸破斷面出現共晶反應生成之Al12Mg17+Mg結構。
腐蝕可靠度方面，參數L2晶粒細小且均勻，形成緊密屏障，帶狀區(BZ)中粗大且連續富Al相，降低電解液滲入與局部腐蝕擴展機會，使其耐腐蝕性最好。L4與L7晶粒較大，帶狀區(BZ)中細長且分散富Al相，界面密度高，增加局部微電偶腐蝕驅動力，使其界面不穩定耐蝕性較差。於鹽霧作用下，攪拌區(SZ)之富Al區與富Mg區生成Al2O3、Al(OH)3、MgO、Mg(OH)2，不穩定的MgO/Mg(OH)2腐蝕產物於鹽霧作用下剝落，在富Mg區留下較深且較大腐蝕面積，最終導致拉伸破斷路徑沿腐蝕深坑延伸，且斷裂行為由MgO/Mg(OH)2主導。
本研究透過田口式方法、相圖模擬、微觀結構分析、機械性能測試與腐蝕可靠度分析，提供一套Al/Mg異材質摩擦攪拌銲接(FSW)參數，並建立了接合處中Al-Mg IMC形成機制以及腐蝕過中之腐蝕流程，對於未來輕量化車輛結構的異材質接技術提供了理論與實務依據，期望能夠促進鋁合金與鎂合金在汽車輕量化的應用發展。

Driven by the global trend toward energy conservation and carbon reduction, automotive lightweighting has become a critical strategy for lowering emissions. Aluminum and magnesium alloys, characterized by low density and high mechanical strength, are widely adopted as ideal lightweight structural materials in vehicles. However, dissimilar joining remains a significant challenge. During Al/Mg welding, excessive formation of brittle Al-Mg intermetallic compounds (IMCs) deteriorates joint strength and elongation. In this study, friction stir welding (FSW), a solid-state joining process, was employed for Al/Mg dissimilar welding to investigate influence of process parameters on IMC formation and joint quality.
The Taguchi method with an L9 orthogonal array was applied to optimize key FSW parameters, including tool rotational speed, welding speed, plunge depth, and tool offset, to identify the optimal condition for superior tensile performance. Heat input under different parameter sets was calculated, and its effects were systematically evaluated through microstructural characterization, mechanical testing, and corrosion reliability analysis.
From a microstructural perspective, Pandat simulations predicted the formation of Al–Mg IMCs, which were confirmed by XRD as Al₃Mg₂ and Al₁₂Mg₁₇. In the stir zone (SZ), IMCs formed via diffusion and eutectic reactions, where diffusion-induced phases exhibited dense lamellar structures and eutectic Al₁₂Mg₁₇ appeared as dispersed particles in the Mg-rich phase. Increasing heat input resulted in a thicker IMC layer, while appropriate heat input promoted coarse and continuous Al-rich phases in the bond zone (BZ). Severe plastic deformation in the SZ induced dynamic recrystallization (DRX), leading to grain refinement, LAGB-to-HAGB transformation, and a strong isotropic texture. With higher heat input, grain growth and recrystallization fraction further increased. In contrast, the Mg-side TMAZ exhibited limited DRX due to lower strain rates, resulting in restricted grain refinement, retained LAGBs, and residual stress accumulation, which was Reduced material flow rate at higher heat input.
Regarding mechanical properties, the presence of continuous Al-rich phases in the BZ facilitated uniform plastic deformation during tensile loading, thereby enhancing tensile strength. However, strain localization intensified in the Mg-side TMAZ due to its coarse grains and strong (0001) basal texture, while the SZ exhibited fine, equiaxed grains with isotropic characteristics. This microstructural incompatibility led to deformation mismatch and ultimately caused fracture to occur preferentially at the SZ/TMAZ interface. Additionally, the loosely distributed eutectic Al12Mg17+Mg structure promoted crack propagation, and such features were observed on the fracture surfaces.
In terms of corrosion behavior, the L2 condition exhibited the best corrosion resistance due to its fine and homogeneous grain structure, which formed an effective barrier, along with coarse and continuous Al-rich phases in the BZ that suppressed electrolyte penetration and localized corrosion. In contrast, L4 and L7 conditions showed inferior corrosion resistance due to coarser grains and elongated, dispersed Al-rich phases in the BZ, which increased interfacial density and enhanced micro-galvanic corrosion susceptibility. Under salt spray exposure, Al2O3, Al(OH)3, MgO, and Mg(OH)2 formed in the SZ. The unstable MgO/Mg(OH)2 corrosion products tended to spall off, leaving deep and corrosion pits in Mg-rich regions. Consequently, tensile fracture paths propagated along these corrosion pits, with fracture behavior dominated by MgO/Mg(OH)2-related degradation.
This study integrates the Taguchi method, phase diagram simulation, microstructural analysis, mechanical testing, and corrosion evaluation to establish an optimized FSW parameter set for Al/Mg dissimilar joints. Furthermore, the formation mechanisms of Al–Mg IMCs and the corrosion evolution process were systematically elucidated. The findings provide both theoretical insight and practical guidance for advancing dissimilar joining technologies in lightweight automotive structures.

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