Effect of Process Parameters on Interfacial Bonding Properties of Aluminium–Copper Clad Sheet Processed by Multi-Pass Friction Stir-Welding Technique

Abstract

In this study, continuous multi-pass friction stir welding was used to clad dissimilar AA6061 aluminium (Al) and C2801P copper (Cu) alloy materials. The empirical relationships between three process parameters and two-factor responses of Al–Cu clad joints were evaluated. Mathematical models were generated using regression analysis to predict the variation in tensile shear and peel load of the cladded joints. The sufficiency of the developed model was validated by analysis of variance (ANOVA), and the multi-criterion optimisation of factor responses was carried out via the response surface method. Results showed the formation of mechanical interlocking at the cladded interface and the development of a thin metallurgical bonding layer consisting of Al alloy content (8–21%), which greatly affected the quality of the Al–Cu joint interface. Moreover, the increase in shoulder overlap ratio, welding speed and tool rotational speed improved the shear and peel strength up to a certain range before gradually declining. The optimised process parameters for the cladded Al–Cu were obtained at a rotational speed of 986 r/min, welding speed of 8.6 mm/min and shoulder overlap ratio of 35%. The cladded Al–Cu generated a shear strength of 5850 kPa and peel strength of 750 kPa with an overall desirability function of 0.94.

Cold-Rolling Strain Hardening Effect on the Microstructure, Serration-Flow Behaviour and Dislocation Density of Friction Stir Welded AA5083

“…The versatility of this strain-hardened alloy renders it ideal for applications related to the automotive industry [3] and for the fabrication of marine structures, pipelines, and aircraft components [4]. Given the problems encountered in the fusion welding of Al alloys, such as porosity [5], cracking [6], and dissolution of precipitation phases [7,8], a solid joining technique known as friction stir welding (FSW) was carried out for the joining of Al alloys [9][10][11][12][13]. In 1991, this welding process was introduced by The Welding Institute [14].…”

On the Application of a Design of Experiments along with an ANFIS and a Desirability Function to Model Response Variables

“…Other studies such as that of Chahal et al [42] show that RSM along with a desirability function is effective in order to optimize surface roughness in end milling; Zhao et al [43] analyze the effect of welding parameters on the mechanical properties of welding bead and welding heat input using a DOE and a desirability function and Kribes et al [44] study the effect of machining conditions on the obtained surface roughness in hard turning by using response surface methodology and a desirability function. Some other studies which employ the response surface methodology and a desirability function are Ahmad et al [45] that optimizes the recycling conditions of aluminum (AA6061) chips, Qazi et al [46] that analyzes the machinability of AA5005H34, and Osman et al [47] that studies continuous multi-pass friction stir welding to clad dissimilar materials. Cutting speed, feed rate, and depth of cut are used as design parameters along with RSM and desirability function in Laghari et al [48] for modeling cutting forces in the machining of a composite material; Pradhan et al [49] analyze surface roughness in machining of Al/SiCp metal matrix composite; optimization of friction surface deposition of stainless steel over medium carbon steel is shown in Sahoo et al [50] and in Du et al [51] a multi-objective optimization is carried out in the dry machining of a 304 stainless steel, among many others.…”

Microstructural Control of the Interface Layer for Strength Enhancement of Dissimilar Al/Cu Joints via Ni Addition during TIG Arc Brazing

“…Therefore, many attempts using low heat-input welding have been made to reduce the thickness of the IMC layer. For instance, the application of brazing between liquid Al and solid Cu, such as arc brazing [12][13][14][15] and laser brazing [16][17][18], and solid-state joining, such as friction welding [19,20], friction stir welding [10,[21][22][23][24], and ultrasonic spot welding [25][26][27], successfully suppressed the growth of the IMC layer, thereby improving the mechanical properties of the dissimilar joints.…”