Microstructure characterization and mechanical behavior of dissimilar friction stir welded Al/Cu couple with different joint configurations

Zhang, Wei; Shen, Yifu; Yan, Yinfei; Guo, Rui; Guan, Wei; Guo, Guolin

doi:10.1007/s00170-017-0961-2

Cited by 39 publications

(20 citation statements)

References 27 publications

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“…The said cracks and voids can be minimized by following methods: studying interaction factors effect, and applying organic compound coating or by keeping the work conditions below normal room temperature (subzero/cryogenic range). 62,63 Figure 12 shows the microstructure obtained at different weld zones: BMZ, SZ, TMAZ and HAZ. The parent or base metal remains unaltered and is not affected by the physical contact between the tool and workpiece (refer to Figure 12a).…”

Section: Results Of Sem Analysis Of Test Specimensmentioning

confidence: 99%

Experimental Investigation and Characterization of Friction Stir Spot-Welded Dissimilar Aluminum Copper Metallic Lap Joints

Devarajan,

Karuppanan,

Duraisamy

et al. 2023

ACS Omega

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Due to their contrasting physical properties, joining materials like copper and aluminum has always proven difficult. The disadvantages of traditional joining methods include additional weight, solidification problems, and energy waste. Friction stir spot-welding (FSSW) was utilized for joining copper and aluminum in order to get around these difficulties. This study illustrates that friction stir spot-welding (FSSW) produces joints between incompatible copper and aluminum alloys with better mechanical and electrical properties. The numerous FSSW parameters play an important role in deciding how well the welded joint performs. Tool rotational speed (TRS), plunge rate (PR), and dwell duration (DT) are the study parameters. During manufacture, a case-hardened H13 tool was used to lap-joint AA 6061 T6 hot-rolled aluminum flat strips with C11000 copper strips while operating at three different levels of TRS, PR and DT. SEM analysis was utilized to investigate the interface region and bimetallic interface of the joints. In order to demonstrate modifications in the grain-related characteristics, the joints were examined for electrical conductivity, mechanical strength (lap shear, bending, and microhardness test), and analysis of the microstructure at the weld zones. The outcome demonstrates that other factors, such as plunge rate, dwell time, and tool rotation speed, had the greatest impact on the joints' electrical conductivity, mechanical strength, and microstructure.

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Section: Results Of Sem Analysis Of Test Specimensmentioning

confidence: 99%

Experimental Investigation and Characterization of Friction Stir Spot-Welded Dissimilar Aluminum Copper Metallic Lap Joints

Devarajan,

Karuppanan,

Duraisamy

et al. 2023

ACS Omega

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“…This method is successfully used in many industries, including aviation, automotive, shipbuilding, spacecraft or railways [2,3]. FSW treatment has great potential for joining similar materials such as aluminum [4,5], copper [6], steel [7] and dissimilar materials such as aluminum and steel [8,9], aluminium and copper [10,11] or aluminium and titanium [12]. In the literature, it can be fi nd also tests of welding of dissimilar alloys with diff erent thicknesses [13].…”

Section: Introductionmentioning

confidence: 99%

The Effect of Brushing on Residual Stress and Surface Roughness of EN AW-2024-T3 Aluminum Alloy Joints Welded Using the FSW Method

Bucior¹,

Kluz²,

Trzepieciński³

et al. 2023

Adv. Sci. Technol. Res. J.

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This article presents the infl uence of the brushing process on residual stress and surface roughness of EN AW-2024-T3 aluminum alloy joints welded using the Friction Stir Welding (FSW) method. Butt joints with thicknesses of 2 mm were brushing with using ceramic brush. The aim of the study was to fi nd optimal parameters of the brushing process, which would signifi cantly improve the functional properties of welded joints. The experiments were carried out in two steps. In the fi rst stage of the research, the feed rate was changed in the range f = 40÷120 mm/min with a constant brushing depth d = 0.5 mm. The roughness decreased from Sa = 5.285 µm for the specimen after welding to Sa = 2.460 µm for the f = 120 mm/min and d = 0.5 mm. The change in the parameters of the brushing process did not have a signifi cant impact on the state of residual stresses. Hence, in the second step, the brushing depth was increased in steps of 0.1 mm. The best properties were obtained for f = 120 mm/min and d = 0.6 mm (variant 6A), where roughness was Sa = 0.443 µm and compressive stresses σ = -118 MPa.

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“…They also found a significant increase in microhardness of the weld zone from 160 HV to 320 HV. Zhang et al [ 18 ] replaced the surface-to-surface joint configuration at the joining area with a tooth-shaped joint configuration for bonding Al/Cu dissimilar metals by using CFSW. This proved a better design to tailor the base materials content into the weld.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties Analysis of Al/Cu Dissimilar Alloys Joining by Using Conventional and Bobbin Tool Friction Stir Welding

et al. 2022

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The feasibility of producing welding joints between 6061-T6 aluminum and pure copper sheets of 6 mm thickness by conventional friction stir welding (CFSW) and bobbin tool friction stir welding (BTFSW) by using a slot-groove configuration at the joining surface was investigated. The microstructure of the welded samples was examined by using an optical microscope and X-ray diffraction. Furthermore, the mechanical properties of the weld samples are compared based on the results of the tensile test, hardness measurement, and fractography test. The slot-groove configuration resulted in the presence of a bulk-sized Al block on the Cu side. The microscopic observations revealed the dispersion of fine Cu particles in the stir zone. The presence of intermetallic compounds (IMCs) CuAl2, which are hard and brittle, lowered the strength of the weld joints. The strength of the weld joints produced with BTFSW was superior to that of the C-FSW. The maximum hardness values of 214 HV and 211 HV are reported at the stir zone for BTFSW and CFSW, respectively. The fracture location of all the joints was at the intersection of the stir zone and the thermomechanically affected zone was on the Cu side.

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Microstructure characterization and mechanical behavior of dissimilar friction stir welded Al/Cu couple with different joint configurations

Cited by 39 publications

References 27 publications

Experimental Investigation and Characterization of Friction Stir Spot-Welded Dissimilar Aluminum Copper Metallic Lap Joints

Experimental Investigation and Characterization of Friction Stir Spot-Welded Dissimilar Aluminum Copper Metallic Lap Joints

The Effect of Brushing on Residual Stress and Surface Roughness of EN AW-2024-T3 Aluminum Alloy Joints Welded Using the FSW Method

Microstructure and Mechanical Properties Analysis of Al/Cu Dissimilar Alloys Joining by Using Conventional and Bobbin Tool Friction Stir Welding

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