The Influence of the Friction Stir Welding Parameters on the Formation of Welded Joint of Aluminum and Copper Alloys

Rzaev, R.A.; Chularis, A. A.; Смирнов, В. В.; Semyenova, Larisa

doi:10.1016/j.matpr.2019.01.025

Cited by 15 publications

(12 citation statements)

References 4 publications

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“…Among the three samples, only sample #5 had no defect. Cu9Al4 was frequently reported in the literature [7][8][9][10][11]14].…”

Section: Weld Morphology and Microstructurementioning

confidence: 96%

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Microstructure and mechanical performance of FSWed joint of T2 copper and AA 1061

Gao

et al. 2020

Science and Technology of Welding and Joining

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Welding of copper and aluminium has been problematic with tradition fusion method. The friction stir welding (FSW) was employed to butt weld the T2 copper and 1061 aluminum alloy plates. The welding parameters were planned by the orthogonal experiment design method. The samples obtained in experiments were investigated in the aspects of microstructure, tensile strength, fatigue performance and micro-hardness.Sound weld with the best tensile strength and fatigue life was produced under the welding parameters of rotation speed, 1100rpm and welding speed 50mm/min. The tensile strength was 193.16MPa, 85% of the base aluminium material. Three intermetallic compounds (IMC) of CuAl, Cu3Al and Cu9Al4 were detected at the copper-aluminium interface in XRD analysis.

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“…Among the three samples, only sample #5 had no defect. Cu9Al4 was frequently reported in the literature [7][8][9][10][11]14].…”

Section: Weld Morphology and Microstructurementioning

confidence: 96%

“…The shape and main sizes of the tool used in this paper are shown in Figure 1. The process parameters have a direct impact on the quality of welded joints [7].…”

Section: Friction Stir Welding Experimentsmentioning

confidence: 99%

Microstructure and mechanical performance of FSWed joint of T2 copper and AA 1061

Gao

et al. 2020

Science and Technology of Welding and Joining

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“…However, there is a considerable difference in the melting points of copper (1356 K) and aluminum (933 K), which makes it challenging to join the two using fusion welding because severe burning loss of aluminum occurs while copper just starts to melt [6,7]. In addition, the differences in the thermal expansivities of Al and Cu and the formation of brittle metallic compounds at the joints cause huge residual stresses and cracks [7][8][9][10].…”

Section: Introductionmentioning

confidence: 99%

“…Various welding methods have been investigated to join aluminum and copper such as explosive welding [8,11,12], friction stir welding (FSW) [10,[13][14][15], electron beam welding (EBW) [16], magnetic pulse welding [17][18][19], diffusion bonding [20,21], cold roll welding [22], laser welding [1,23], and brazing [24][25][26]. These studies have mostly focused on two ways for optimizing layers of intermetallic compounds (IMCs), namely, adding other elements to the metallurgical reaction system to avoid brittle IMC phases, such as θ (Al 2 Cu)), η (AlCu), or γ (Al 4 Cu 9 ) phases [27], and limiting the thicknesses of IMC layers by optimizing process parameters.…”

Section: Introductionmentioning

confidence: 99%

Effects of Different Types of Interlayers on the Interfacial Reaction Mechanism at the Cu Side of Al/Cu Lap Joints Obtained by Laser Welding/Brazing

et al. 2021

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The influence of tin foil and Ni coatings on microstructures, mechanical properties, and the interfacial reaction mechanism was investigated during laser welding/brazing of Al/Cu lap joints. In the presence of a Zn-based filler, tin foil as well as Ni coating strengthened the Al/Cu joints. The tin foil only slightly influenced the joint strength. It considerably improved the spreading/wetting ability of the weld filler; however, it weakened the bonding between the seam and the Al base metal. The Ni coating considerably strengthened the Al/Cu lap joints; the highest tensile strength was 171 MPa, which was higher by 15.5% than that of a joint without any interlayer. Microstructure analysis revealed that composite layers of Ni3Zn14–(τ2 Zn–Ni–Al ternary phase)–(α-Zn solid solution)–Al3Ni formed at the fusion zone (FZ)/Cu interface. Based on the inferences about the microstructures at the interfaces, thermodynamic results were calculated to analyze the interfacial reaction mechanism. The diffusion of Cu was limited by the Ni coating and the mutual attraction between the Al and Ni atoms. The microstructure comprised Zn, Ni, and Al, and they replaced the brittle Cu–Zn intermetallic compounds, successfully strengthening the bonding of the FZ/Cu interface.

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“…This process was primarily used for joining aluminium and aluminium alloys (Thomas and Nicholas, 1997). Over the past decade, researchers have also successfully welded dissimilar metals such as aluminium alloys (Devaiah, Kishore and Laxminarayana, 2018;Elnabi et al, 2018;Muthu Krishnan et al, 2018;Abd Elnabi et al, 2019;Eskandari et al, 2019), aluminium alloys and copper (Zhang et al, 2014;Aliha et al, 2019;Muhammad and Wu, 2019;Rzaev et al, 2019;Shankar et al, 2019), aluminium and brass (Esmaeili et al, 2011b(Esmaeili et al, , 2011b(Esmaeili et al, , 2012Shojaeefard et al, 2013;Elfar et al, 2016), aluminium and magnesium (Jayaraj et al, 2017;Paradiso et al, 2017;Abdollahzadeh et al, 2019;Md and Birru, 2019), aluminium and nickel (Zheng et al, 2017), aluminium and steel (Kasai et al, 2015;Pourali et al, 2017;Hatano et al, 2018;Helal et al, 2019) and aluminium and titanium (Wu et al, 2015;Choi et al, 2018;Yu et al, 2019). The FSW process produces a weld with minimum defects as compared to fusion welding.…”

Section: Introductionmentioning

confidence: 99%

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

Panaskar

Terkar

2020

WJE

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Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

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The Influence of the Friction Stir Welding Parameters on the Formation of Welded Joint of Aluminum and Copper Alloys

Cited by 15 publications

References 4 publications

Microstructure and mechanical performance of FSWed joint of T2 copper and AA 1061

Microstructure and mechanical performance of FSWed joint of T2 copper and AA 1061

Effects of Different Types of Interlayers on the Interfacial Reaction Mechanism at the Cu Side of Al/Cu Lap Joints Obtained by Laser Welding/Brazing

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

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