Experimental Analysis and Mathematical Model of FSW Parameter Effects on the Corrosion Rate of Al 6061-T6-Cu C11000 Joints

Abstract

Friction stir welding is characterized as an ecological and low-cost process in comparison to traditional welding techniques, and due to its application in the solid state, it is a feasible option for joining similar and/or dissimilar materials. The present investigation seeks to determine the effect of friction stir welding’s parameters on the corrosion resistance of an Al 6061-T6–Cu C11000 dissimilar joint, with mathematical analysis to validate the results. After the welding process, the samples were exposed to a NaCl solution in an electrochemical cell to determine the corrosion rate via potentiodynamic tests. Microstructural characterization revealed a laminar structure, composed of aluminum and copper, as well as copper particles and the formation of intermetallic compounds distributed in the weld zone. The potentiodynamic tests showed that the corrosion rate increased with the rotational and traverse speeds. The mathematical model quantifies the relationship between corrosion rate and rotational and traverse speeds.

A review on recent development in aluminium-copper friction stir welding

“…Bora et al found maximum tensile strength at high rotational speeds and constant welding speed. 86 A decrease in welding speed at constant rotational speed produces a large amount of intermetallic because of the high heat supply, 87 while an increase in welding speed at constant rotational speed produces low heat in the joint area. [88][89][90] According to Montes et al, at greater welding speeds and constant rotational speeds, the corrosion rate increases, and it was stronger at higher rotational speeds and constant welding speeds.…”

“…[88][89][90] According to Montes et al, at greater welding speeds and constant rotational speeds, the corrosion rate increases, and it was stronger at higher rotational speeds and constant welding speeds. 87 For a defect-free joint, researchers suggest a low welding speed and a high rotational speed. Tool get more time to soft the material at low welding speed and produce defect-free joints.…”

Influence of process parameters on the mechanical properties and corrosion resistance of dissimilar friction stir welded joints of AA2024-O and AA6061-O aluminum alloys

“…The critical factors observed in fusion welding processes are related to changes in the liquid-solid state (including hot cracking and HAZ liquation), the melting temperature, the cooling rates, and the phase transformations, among others. These discontinuities could be drastically reduced using FSW, obtaining welded joints with good mechanical properties and acceptable corrosion resistance [7][8][9][10]. Key metallurgical factors in FSW that aim to obtain good mechanical properties and corrosion resistance are grain size refinement and intermetallic precipitate distribution [11][12][13].…”

An Investigation into Microstructures and Mechanical Properties of 1060 Pure Aluminum during Submerged Friction Stir Processing at a High Rotating Speed

“…The rotating speed of the tool is always one of the main parameters that affect the performance of SZ. In the published literature, the stirring head speed of various materials in FSP is mostly based on a low rotating speed (200-2000 r/min), as shown in Figure 1 [6][7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25], and there are few studies on FSP at higher rotating speeds (≥3000 r/min). Scholars [26] believe that heat input in FSW and FSP processes can be reduced at a low rotating speed, so as to obtain better weld quality.…”