Microstructural aspects in Al–Cu dissimilar joining by FSW

Carlone, Pierpaolo; Astarita, Antonello; Palazzo, Gaetano Salvatore; Paradiso, Valentino; Squillace, Antonino

doi:10.1007/s00170-015-6874-z

Cited by 104 publications

(30 citation statements)

References 29 publications

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“…Friction stir welding (FSW) is a solid state welding technique employed for joining several similar as well as dissimilar materials pairs, generally considered difficult to weld using conventional welding techniques [1][2][3][4][5]. The main benefits provided by FSW over conventional fusion welding processes can be summarized in the reduction of porosity, of microstructure alteration and of process induced residual stresses and distortions.…”

Section: Introductionmentioning

confidence: 99%

Multiple crack growth prediction in AA2024-T3 friction stir welded joints, including manufacturing effects

Carlone

Citarella

Sonne

et al. 2016

International Journal of Fatigue

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A great deal of attention is currently paid by several industries toward the friction stir welding process to realize lightweight structures. Within this aim, the realistic prediction of fatigue behavior of welded assemblies is a key factor. In this work an integrated finite element method–dual boundary element method (FEM–DBEM) procedure, coupling the welding process simulation to the subsequent crack growth assessment, is proposed and applied to simulate multiple crack propagation, with allowance for manufacturing effects. The friction stir butt welding process of the precipitation hardened AA2024-T3 alloy was simulated using a thermo-mechanical FEM model to predict the process induced residual stress field and material softening. The computed stress field was transferred to a DBEM environment and superimposed to the stress field produced by a remote fatigue traction load applied on a notched specimen. The whole procedure was finally tested comparing simulation outcomes with experimental data. The good agreement obtained highlights the predictive capability of the method. The influence of the residual stress distribution on crack growth and the mutual interaction between propagating cracks were analyzed as well

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Section: Introductionmentioning

confidence: 99%

Multiple crack growth prediction in AA2024-T3 friction stir welded joints, including manufacturing effects

Carlone

Citarella

Sonne

et al. 2016

International Journal of Fatigue

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“…Ouyang et al 9 and Carlone et al 10 described that the chemical affinity of aluminium and copper can lead to the formation of intermetallic phases such as CuAl 2 , CuAl, Al 3 Cu 4 and Cu 9 Al 4 , whose effects can be deleterious, and Bisadi 8 concluded that the amount of intermetallic compounds formed in the stir zone increases with temperature.…”

Section: Introductionmentioning

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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“…However, the reason of the work-piece configuration was not explained in detail [20]. According to the investigation of dissimilar FSW between Al and Cu alloys, the suitable configuration and even the amount of offset of the tool from the joint centerline were considered to play an important role in obtaining high joints properties [21][22][23]. More recently, Sun et al conducted the dissimilar spot FSW between the UFGed 1050Al and 6061-T6 aluminum alloys [24].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Dissimilar Friction Stir Welding between Ultrafine Grained 1050 and 6061-T6 Aluminum Alloys

Yangshan

Tsuji

Fujii

2016

Metals

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Abstract:The ultrafine grained (UFGed) 1050 Al plates with a thickness of 2 mm, which were produced by the accumulative roll bonding technique after five cycles, were friction stir butt welded to 2 mm thick 6061-T6 Al alloy plates at a different revolutionary pitch that varied from 0.5 to 1.25 mm/rev. In the stir zone, the initial nano-sized lamellar structure of the UFGed 1050 Al alloy plate transformed into an equiaxial grain structure with a larger average grain size due to the dynamic recrystallization and subsequent grain growth. However, an equiaxial grain structure with a much smaller grain size was simultaneously formed in the 6061 Al alloy plates, together with coarsening of the precipitates. Tensile tests of the welds obtained at different welding speeds revealed that two kinds of fracture modes occurred for the specimens depending on their revolutionary pitches. The maximum tensile strength was about 110 MPa and the fractures were all located in the stir zone close to the 1050 Al side.

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Microstructural aspects in Al–Cu dissimilar joining by FSW

Cited by 104 publications

References 29 publications

Multiple crack growth prediction in AA2024-T3 friction stir welded joints, including manufacturing effects

Multiple crack growth prediction in AA2024-T3 friction stir welded joints, including manufacturing effects

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

Microstructure and Mechanical Properties of Dissimilar Friction Stir Welding between Ultrafine Grained 1050 and 6061-T6 Aluminum Alloys

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