Linear friction welding of Al–Cu: Part 1 – Process evaluation

Wanjara, P.; Dalgaard, E.; Trigo, Gil; Mandache, Catalin; Comeau, G.; Jonas, John J.

doi:10.1179/000844311x13112418194644

Cited by 29 publications

(22 citation statements)

References 4 publications

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“…Moreover, a high affinity for Al/Cu assembly at temperatures >120°C is also beneficial to interfacial alloying. 26) With increasing the time for scrubbing along the new actual interface, no gap or cracking was found (Fig. 6(c) and (d)), and both initial interface and secondary interface could be sequentially bonded well by alloying via detectable diffusion over ³2 µm.…”

Section: Resultsmentioning

confidence: 99%

“…25) In linear friction welding of Cu/6063Al of 13 mm © 26 mm area to be welded, the Al and Cu remained contact but distinct, and Cu particles were entrained in the thermo-mechanically affected zone (TMAZ) on 6063Al side, especially for lower power input for relatively long friction time. 26) In contrast to the mixing layer or turbulent zones mainly consisting of Cu particle and deformed Al matrix formed by very high pressure (40³75 MPa) in general rotary and linear friction welded joint, the continuous layer-like morphology of interfacial microstructure formed in the Al/Cu USW joint suggested that the layer-shaped interfacial phase should be finally formed by an surficial alloying activated by high shear deformation rate (and/or degree) under ultrasonic slipping at lower temperature (called ultrasonic mechanical alloying), rather than only or major mechanical mixing. Moreover, a high affinity for Al/Cu assembly at temperatures >120°C is also beneficial to interfacial alloying.…”

Section: Resultsmentioning

confidence: 99%

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Ultrasonic Weldability of Al Ribbon to Cu Sheet and the Dissimilar Joint Formation Mode

et al. 2015

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This work aims to investigate the ultrasonic weldability of Al ribbon (width 2.0 mm © thickness 0.2 mm) to Cu sheet (thickness 1.0 mm) using a WC tool of 2.0 mm © 1.0 mm (sonotrode tip size) and to understand joint formation process by examining joint microstructures and fracture behavior for different bonding times. For the selected conditions of 20 W power, 30 N clamping force, 0.10.8 s bonding time, it was found that sound lap joints could be readily obtained when the bonding time reached and exceeded 0.4 s, which fractured within Al ribbon, but not along interface, owing to the formation of dense and thin alloying layer of 2³3 µm thickness with a continuous composition gradient. When such bonding has been established, the actual slipping motion shifted upwards to the top of Al ribbon. On the other hand, both microstructure and fracture surface observations indicated that in the early stage, localized adhesion occurred accompanied by the detachment of just adhered Al part from remaining Al ribbon body, leading to a cracking (called secondary interface) within weak Al ribbon. Thus, USW of Al ribbon to Cu sheet was achieved through a series of slipping at three kinds of transient interfaces: localized adhesion at original interface and alloying of the adhered Al together with detachment within Al ribbon (forming the secondary interface); re-bonding at the secondary interface together with further bonding at original interface under resisted slipping and high frictional coefficient as a result of surface roughening by previous isolated compound formation at original interface; and final upwards shifting of slipping to the third interface between top surface of Al ribbon and tool end.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Ultrasonic Weldability of Al Ribbon to Cu Sheet and the Dissimilar Joint Formation Mode

et al. 2015

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“…In order to join compact or rotationally symmetric work pieces, Wanjara et al [23] and Wei et al [24] as well as Lee et al [25] showed the good applicability of linear friction welding and continuous drive friction welding for Al-Cu joints, respectively. Dependent on the process control, IMC formation can be minimized to a total thickness of maximum 5-10 µm.…”

Section: Introductionmentioning

confidence: 99%

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

Regensburg

Schürer

Weigl³

et al. 2018

Metals

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Abstract:The fabrication of dissimilar joints for electrical applications raises challenges for conventional joining technologies. Within solid-state processes, friction stir welding (FSW) provides numerous advantages to realize different joint configurations. However, depending on the intermixing of the materials, defects like hooking and significant intermetallic compound formation around copper fragments are observed and lead to a decrease in joint properties. Therefore, stationary shoulder FSW was applied to produce 2 mm EN AW1050/CW024A lap joints with minimized intermixing at the interface. Compared to conventional FSW, the range of the friction-based heat input can be increased without risking excessive plastification under the tool shoulder. The influence of the pin length on the interfacial structure as well as the mechanical properties were investigated. A pin length of 2.2 mm and hence a plunging of approximately 0.2 mm into the lower copper sheet was found to obtain the highest failure load. A further increase caused the formation of hooking defects, which led to void formation at the interface and failure within the area of the thinned aluminium sheet. The results were also transferred to lap joints with a tin and silver interlayer of 10 µm and also showed good results in terms of bond strength and contact area.

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“…A few reports have discussed the LFW of aluminium (AA 6063) to oxygen free copper, 7,8 and it was found that welds with good electrical properties could be produced. However, no details of the mechanical properties of these welds were reported.…”

Section: Introductionmentioning

confidence: 99%

Linear friction welding of aluminium to copper

Bhamji

Moat

Preuss

et al. 2012

Science and Technology of Welding and Joining

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The joining of dissimilar materials is attaining increasing importance as there is a drive to utilise hybrid structures and reduce the weight or cost of products. The present work therefore studied the linear friction welding of commercially pure grades of aluminium to copper (AA 1050 to C101) for potential power transmission applications. Results showed that welds with very good mechanical and electrical properties can be produced. The weld microstructure was analysed using optical microscopy, backscattered scanning electron microscopy, hardness testing and high energy synchrotron X-ray diffraction. These techniques were used in order to identify any cross-weld grain size variations and possible formation of intermetallic phases close to the weld line.

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Linear friction welding of Al–Cu: Part 1 – Process evaluation

Cited by 29 publications

References 4 publications

Ultrasonic Weldability of Al Ribbon to Cu Sheet and the Dissimilar Joint Formation Mode

Ultrasonic Weldability of Al Ribbon to Cu Sheet and the Dissimilar Joint Formation Mode

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

Linear friction welding of aluminium to copper

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