Friction welding of StAl and AlCu materials

Yilbaş, Bekir Sami; Şahin, Ahmet Z.; Kahraman, Nafiz; Al‐Garni, Ahmed Z.

doi:10.1016/0924-0136(94)01349-6

Cited by 139 publications

(53 citation statements)

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“…diffusion joining or friction joining such as rotary friction welding (referred to as the friction welding) can minimize IMC generation. Many researchers have reported that the mechanical and metallurgical properties of friction welded joints between Al-system material and Cu-system material show desirable characteristics (Ando, et al, 1963;Wang, 1975;Kaga, et al, 1981;Morozumi and Kikuchi, 1982;Dawson, 1983;Hasui, et al, 1986;Aritoshi, et al, 1991;Yilbaş, et al, 1995;Itoh, et al, 1998;Lee, et al, 2005;Ochi, et al, 2007;Ratković, et al, 2009;Sahin, 2010). However, several joints of this combination, which were affected by the IMC that was generated at the weld interface, had brittle fractures themselves in the IMC (Aritoshi, et al, 1991;Itoh, et al, 1998;Lee, et al, 2005).…”

Section: Introductionmentioning

confidence: 99%

Joining phenomena and tensile strength of friction welded joint between pure aluminum and pure copper

Kimura

Inui

Kusaka

et al. 2015

Mechanical Engineering Journal

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This paper describes the joining phenomena and the tensile strength of friction welded joint between type 1070 pure aluminum (CP-Al) and oxygen free copper (OFC). When the joint was made at a friction pressure of 30 MPa with a friction speed of 27.5 s −1 , the upsetting (deformation) occurred at the CP-Al side. When the joint was made at a friction time of 2.0 s, the whole weld interface on the OFC side had the transferred CP-Al, and it was obtained approximately 30% joint efficiency. Then, the joint efficiency increased with increasing friction time, and it was obtained approximately 63% joint efficiency at a friction time of 12.0 s. The joint fractured at the weld interface, which had a CP-Al adhering to the weld interface on the OFC side. When the joint was made with friction times of 2.0 s and 6.0 s, the joint efficiency increased with increasing forge pressure and then the joint was obtained the CPAl side fracture at a forge pressure of 135 MPa or higher. However, the joint did not achieve 100% joint efficiency because the adjacent region of the weld interface at the CP-Al side was softened. In addition, the joint at a friction time of 2.0 s had no intermetallic compound (IMC) layer at the weld interface although the not-joined region was slightly observed. On the other hand, the joint at a friction time of 6.0 s did not have the not-joined region at the weld interface although the IMC layer was slightly observed. In conclusion, to obtain higher joint efficiency with fracture on the CP-Al side, the joint should be made with higher forge pressure, and with the suitable friction time at which the entire weld interface of the OFC side had the transferred CP-Al. IntroductionBecause an expansion in the use of dissimilar metal joints (referred to as dissimilar joints) is expected and widely used in various component parts, easily welding method for dissimilar metal joints is required. On the other hand, dissimilar welding operations have several severe problems in industrial usage. One problem will occur when the dissimilar joints are welded by using fusion welding processes which conventionally produce intermediate layer (interlayer) consisting of brittle intermetallic compound (IMC) at the joint interface of both base metals to be joined. The interlayers usually give detrimental damages on mechanical and metallurgical properties of dissimilar joints (For example, American Welding Society, 1982). In particular, fusion welded joints between aluminum or its alloys (referred to as the Al-system material) and copper or its alloys (referred to as the Cu-system material) have also some problems, e.g. the generation of blowholes and cracks at the joint interface (For example, Mizuno et al., 1999). Therefore, a welding process is urgently required, which will reduce the degradation of the mechanical and metallurgical properties of the joints between Al-system material and Cu-system material. 1

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Section: Introductionmentioning

confidence: 99%

Joining phenomena and tensile strength of friction welded joint between pure aluminum and pure copper

Kimura

Inui

Kusaka

et al. 2015

Mechanical Engineering Journal

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“…However, if it is too deep, it causes over heating which leads to the generation of large amounts of IMC. Yilbas et al 32 report that small amount of intermetallic phases improve the tensile strength of the Al-Cu welds, while a large amount results in poor strength.…”

Section: Microstructurementioning

confidence: 99%

Effect of Heat Input on the Mechanical Behaviour of Al-Cu FSW Lap Joints

et al. 2018

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Dissimilar Al-Cu joints are desirable due to the combination of the good electrical and thermal properties of copper with the economic advantages of aluminium. However, different chemical, mechanical and thermal properties turn dissimilar welding into a challenge with traditional fusion welding techniques. Friction stir welding appears to be a good alternative to welding dissimilar materials. Most of the works in Al-Cu FSW have been performed with Al on top. This work investigates the influence of heat input on the shear strength of aluminium-copper lap joints produced by FSW with a copper over aluminium lap configuration. Welds produced with the ω/ν rate of 200 rev.mm -1 or 500 rev.mm -1 resulted in the melting of the base materials and material leaking. Joints with shear tensile strength varying from 76 to 85% of the original resistance of AA6060 T5 were produced when the ω/ν rate was varied from 80 to 110 rev.mm -1 . The fracture was governed by tension overload on the aluminium sheet, resulting in little influence of welding defects, such as tunnelling, on the joint strength.

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“…Clean welding surfaces are also of prime importance. [13][14][15] In welded St-Cu joints, the joint strength increases with the increasing upset pressure up to the critical value. An increase in the friction time causes a lower strength of a St-Cu joint compared to the Cu base metal.…”

Section: Introductionmentioning

confidence: 99%

Optimizing the parameters for friction welding stainless steel to copper parts

Şahin¹

2016

Mater. Tehnol.

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St-Cu (stainless steel and copper) parts were friction welded with the aim to optimize the process parameters in the present study. The joints obtained with various process-parameter combinations were subjected to a tensile test. Empirical relationships were developed to predict the strength of the joints using RSM (the response-surface methodology) and the coherency of the model was tested. The tensile properties, microhardness variations, SEM, the EDS analysis and X-ray diffraction (XRD) analysis of the welded specimens were evaluated. It was found, with an ANOVA analysis, that the friction pressure/friction time relation has the largest influence on the tensile strength of the joints followed by the rotational speed. However, it was also found that the formation of intermetallics at the interface is responsible for a higher hardness and lower tensile strength of the friction-welded stainless steel-copper joints. Keywords: friction welding, metallurgy, response-surface methodology, tensile strength V predstavljenem delu so bili deli St-Cu (nerjavno jeklo in baker) torno varjeni z namenom optimizacije procesnih parametrov. Spoji, dobljeni z razli~nimi procesnimi parametri, so bili preizku{eni z nateznim preizkusom. Razvite so bile empiri~ne odvisnosti za napovedovanje trdnosti spojev s pomo~jo RSM (Metodologija odgovora povr{ine) in izvr{ena je bila koherenca modela. Ocenjene so bile natezne lastnosti, spreminjanje mikrotrdote, SEM, EDS analiza in rentgenska difrakcija (XRD) zvarjenih vzorcev. Iz ANOVA analize je bilo ugotovljeno, da ima torni tlak/~as trenja najve~ji vpliv na natezno trdnost spojev, sledi pa mu hitrost vrtenja. Ugotovljeno je bilo, da je ve~ja trdota in manj{a natezna trdnost torno varjenih spojev posledica nastanka intermetalne zlitine na stiku nerjavno jeklo-baker. Klju~ne besede: torno varjenje, metalurgija, metodologija odgovora povr{ine, natezna trdnost

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Friction welding of StAl and AlCu materials

Cited by 139 publications

References 1 publication

Joining phenomena and tensile strength of friction welded joint between pure aluminum and pure copper

Joining phenomena and tensile strength of friction welded joint between pure aluminum and pure copper

Effect of Heat Input on the Mechanical Behaviour of Al-Cu FSW Lap Joints

Optimizing the parameters for friction welding stainless steel to copper parts

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