Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al–Cu joints

Xue, P.; Ni, D.R.; Wang, D.; Xiao, B.L.; Y., Z.

doi:10.1016/j.msea.2011.02.067

Cited by 355 publications

(210 citation statements)

References 21 publications

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“…The knowledge of the mechanical properties of the dissimilar friction stir welds between Aluminium and Copper is of importance to enhance their use in the industries. According to Xue et al [2], the hardness increased in the layered structure due to the strengthening effect of intermetallic compounds. Shukla and Shah [3] found that the maximum tensile strength of Al/Cu joint was low (62.2 Mpa) mainly due to the presence of intermetallic compounds.…”

Section: Literature Reviewmentioning

confidence: 99%

Design, Fabrication and Testing of Friction Stir Welded Joints

Nadim¹,

Ahmed²

2014

IJIRSET

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ABSTRACT:Friction-stir welding (FSW) is a solid-state joining process that uses a third body tool to join two faying surfaces. Frictional heat between the welding tool and the work pieces causes the latter to soften without reaching the melting point, allowing the tool to traverse along the weld line. It then mechanically intermixes the two pieces of metal at the place of joint; the softened metal can be joined using mechanical pressure (which is applied by the tool), much like joining clay or dough. In this project, CNC Milling Machine is used to weld the parts together. The parts being welded are made up of dissimilar materials like Aluminum and Copper. The rotational speed is varied from 900 rpm to 1500 rpm while the welding speed is kept constant at 25 mm/min. The other parameter involved is the axial load, which reaches 200 bars. The dimensions of the parts are (100mmx50mmx3mm) which are welded to form a butt joint. The effect of different tool pin profiles on the quality of the welded joint is also studied for welding. Different tool pin profiles considered are threaded, taper, circular/round and square. The tools are designed using Pro/E and are manufactured on a Lathe machine. After the parts are welded, various practical tests are performed on the welded parts that include the tensile strength, microstructure study and the Vickers's hardness test. The experimental results proved that the highest tensile strength of the welded joint i.e., 81.073 N/mm 2 was achieved with the threaded tool profile at speed 900 rpm with feed 25 mm/min and the highest hardness value of 267HV was achieved with the round tool profile at 1500 rpm and feed of 25 mm/min.

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Section: Literature Reviewmentioning

confidence: 99%

Design, Fabrication and Testing of Friction Stir Welded Joints

Nadim¹,

Ahmed²

2014

IJIRSET

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“…The sound joint structure at the nugget zone of alu miniu m was made of a co mposite structure, consisting of brass particles and intermetallic, especially at the upper reg ion of the weld cross section. Also P. Xue et al [4] investigated the effect of rotational speed and pin offset on mechanical p roperties and microstructure of the dissimilar FSW joint of alu miniu m 1060 to pure copper. The sound joint with 110 M Pa ult imate tensile strength (UTS) (84.6% of A l base metal) was produced at 600 rpm rotational speed and 2 mm pin offset to aluminium.…”

Section: Fsw Parametersmentioning

confidence: 99%

Process Parameters Optimization for Friction Stir Welding of Pure Aluminium to Brass (CuZn30) using Taguchi Technique

Elfar

Rashad

Megahed

2016

MATEC Web of Conferences

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Abstract. In this research, the friction stir welding of dissimilar commercial pure aluminium and brass (CuZn30) plates was investigated and the process parameters were optimized using T aguchi L9 orthogonal array. T he considered process parameters were the rotational speed, traverse speed and pin offset. The optimum setting was determined with reference to ultimate tensile strength of the joint. The predicted optimum value of ultimate tensile strength was confirmed by experimental run using optimum parameters. Analysis of variance revealed that traverse speed is the most significant factor in controlling the joint tensile strength and pin offset also plays a significant role. In this investigation, the optimum tensile strength is 50% of aluminium base metal. Metallographic examination revealed that intermetallic compounds were formed in the interface of the optimum joint where the tensile failure was observed to take place.

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“…Friction stir welding is mainly used to weld aluminum and its alloys, resulting strong joints with good plasticity, although aluminum is difficult to weld by conventional methods [3]. Current research in the field are oriented towards welding dissimilar materials (welded plates have different materials) used especially in the construction of parts specific to the aerospace industry, transport, automotive industry, electric power industry [4][5]. Aluminum and copper are two common metals in the electric power industry, but the dissimilar combination of aluminum and copper is generally difficult for fusion welding because of the wide difference in their physical, chemical and mechanical properties [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

Preliminary study on the microstructure and mechanical properties of dissimilar joints of aluminum alloy and pure copper by FSW

et al. 2017

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Abstract. Aluminum and copper are two common metals and Al-Cu joints are commonly used in the power industry. Overlay joints of 3105 aluminum alloy and commercially pure copper were produced by FSW, microstructure and mechanical properties was investigated. A combination of optical and scanning electron microscopy is used to characterize the microstructures in the copper and heat affected zone in the aluminum near the fusion line. The hardness distribution was analyzed and residual stresses were measured at the stir zone, copper side and aluminum alloy side.

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Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al–Cu joints

Cited by 355 publications

References 21 publications

Design, Fabrication and Testing of Friction Stir Welded Joints

Design, Fabrication and Testing of Friction Stir Welded Joints

Process Parameters Optimization for Friction Stir Welding of Pure Aluminium to Brass (CuZn30) using Taguchi Technique

Preliminary study on the microstructure and mechanical properties of dissimilar joints of aluminum alloy and pure copper by FSW

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