Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al–Cu joints (original) (raw)
Related papers
Aerospace Mechanics Journal, 2015
Friction Stir Welding (FSW) is a solid-state welding process used for welding similar and dissimilar materials. FSW is especially suitable to join sheet Al alloys, and this technique allows different material couples to be welded continuously. In this study, 1050 Al alloys and commercially pure Cu were produced at three different tool rotation speeds (630, 1330, 2440 rpm) and three different tool traverse speeds (20, 30, 50 mm/min) with four different tool position (0, 1, 1.5, 2 mm) by friction stir welding. The influence of the welding parameters on the microstructure and mechanical properties of the joints was investigated. Tensile and bending tests and microhardness measurements were used to determine the mechanical properties. The microstructures of the weld zone were investigated by optical microscope and scanning electron microscope (SEM) and were analyzed in an energy dispersed spectrometer (EDS). Intermetallic phases were detected based on the X-ray diffraction (XRD) analysis results that evaluated the formation of phases in the weld zone. When the welding performance of the friction stir welded butt joints was evaluated, the maximum value obtained was 89.55% with a 1330 rpm tool rotational speed, 20 mm/min traverse speed and a 1 mm tool position configuration. The higher tensile strength is attributed to the dispersion strengthening of the fine Cu particles distributed over the Al material in the stir zone region.
In this study, dissimilar sheets of commercially available pure aluminium and copper, were butt joined by friction stir welding (FSW) with a thickness of 3mm to explore the effect of tool rotational speeds on microstructures and mechanical properties experimentally. Three rotational speeds of 1000, 1750 and 2000 rpm were applied. The transverse speed and the axial force were kept constant at 30 mm/min and 7.5 KN, respectively. The cylindrical shoulder and conical pin tool was used to produce the joints. Macrostructures, microstructures, X-ray diffraction (XRD), Vickers microhardness and tensile strength were investigated at these different rotational speeds. The joint welded at 1750 rpm was compared with their counterparts and observed significantly better. The formation of relatively hard brittle intermetallic compounds (Al2Cu and Al4Cu9) were observed with the joint fabricated at rotational speed of 2000 rpm. The results of microhardness (HV) at the nugget zone (NZ) were superior ...
In this study, dissimilar sheets of commercially available pure aluminium and copper, were butt joined by friction stir welding (FSW) with a thickness of 3mm to explore the effect of tool rotational speeds on microstructures and mechanical properties experimentally. Three rotational speeds of 1000, 1750 and 2000 rpm were applied. The transverse speed and the axial force were kept constant at 30 mm/min and 7.5 KN, respectively. The cylindrical shoulder and conical pin tool was used to produce the joints. Macrostructures, microstructures, X-ray diffraction (XRD), Vickers microhardness and tensile strength were investigated at these different rotational speeds. The joint welded at 1750 rpm was compared with their counterparts and observed significantly better. The formation of relatively hard brittle intermetallic compounds (Al2Cu and Al4Cu9) were observed with the joint fabricated at rotational speed of 2000 rpm. The results of microhardness (HV) at the nugget zone (NZ) were superior to those of thermomechanically affected zone (TMAZ), heat affected zones (HAZ) and the base metal (BM). At the rotational speed of 1750 rpm, the tensile strength was higher than other joints. The examination of fractural surface showed that when the dissimilar joints were affected with increasing rotational speeds or heat input; the fracture mode had a tendency to change from ductile to brittle mode.
Materials
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 ...
Microstructure and Properties of Copper and 5754 Aluminum Alloy Joints by Friction Stir Welding
Revista de Chimie
Welding dissimilar materials aluminum and copper by FSW are of great interest because Al and Cu are two most common engineering materials widely used in many industries. The paper analyzes the microstructure and mechanical properties obtained by butt of dissimilar material Cu - Al alloys (EN-AW-5754) by FSW. The joining by FSW process of the two samples (5 mm thickness) was performed with the pin of the tool tangential to copper plate. The values of the process parameters were the same in both cases: the rotation speed of the pin 1200 [rpm] and feed rate 60 [mm / min]. The microstructure was examined in 6 zones covering the whole thickness of the plates, Vickers microhardness was measured along a perpendicular line to the nugget and residual stresses.
The International Journal of Advanced Manufacturing Technology, 2019
Al-Cu joints are used in the electrical industry because of its unique mechanical, thermal and corrosion resistance properties. The present investigation concentrates on understanding the influence of traverse speed on friction stir welded butt joints of 3-mmthick AA 6061-T6 and pure copper. The welds were produced by varying the traverse speed (30 mm/min, 90 mm/min and 150 mm/min) at a constant rotational speed of 800 rpm. Changes in microstructure and mechanical properties with the change in forces generated during the welding were observed and analysed. Energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) analyses revealed the formation of AlCu, Al 2 Cu and Al 4 Cu 9 phases at low and moderate speeds (30 mm/min and 90 mm/ min), whereas at higher traverse speed (150 mm/min), iron aluminide phases (Fe 2 Al 5 and FeAl 3) formed along with Al-Cu phases. These iron aluminium phases act as initial promoters for fracture. The hardness values for all welding parameters were mapped which show hardness variation due to the inhomogeneous distribution of precipitates within the NZ. This is due to different thermal cycles for aluminium and copper as the tool passes the joint line. The tensile strength was measured and found to be maximum at a traverse speed 90 mm/min.
Mechanical and Micro-structural Study of Friction Stir Welding of Al-alloy
International Journal of Applied Research in Mechanical Engineering, 2012
The present study is on the development of friction stir welding (FSW) of commercial grade Al-alloy to study the mechanical and microstructural properties. The proposed research will include experiments related to the effect of FSW optimum process parameter on weldability of Al alloy. The present paper has been subdivided in to two different sections: 1. Study of Mechanical properties and 2. Study of micro-structural properties. Section1 describes the tensile strength of welded sample and distribution of microhardness in different zones of FSW weld specimen and section2 contains the microstructure characterization of different zones of friction stir welds.
EFFECT OF FRICTION STIR WELDING PROCESS ON MECHANICAL AND THERMAL BEHAVIOR OF DISSIMILAR MATERIALS
Friction stir welding (FSW) is a relatively new, state-of the-art solid state joining process. This metal joining technique is derived from the conventional friction welding. In a typical FSW, a rotating cylindrical pin tool is forced to plunge into the plates to be welded (i.e. work piece) and moved along their contact line. During this operation, frictional heat that is generated by contact friction between the tool and work piece softens the material. The plasticized material is stirred by the tool and forced to " flow " to the side and the back of the tool as the tool advances. As the temperature cools down, a solid continuous joint between the two plates is then formed. Because the highest temperature in the FSW process is lower than the melting temperature of the work piece material, FSW yields fine microstructures, absence of cracking, low residual distortion and no loss of alloying elements that are the main advantages of this solid phase process. Nevertheless, as in the traditional fusion welds, a softened heat affected zone and a tensile residual stress parallel to the weld also exist. In this context we have applied this technique to weld Al-Al, Cu-Cu and Al-Cu couples. We studied the effect of experimental parameters like rotational and transverse speed on welding of above metals and consequent microstructure at interface and mechanical properties especially hardness and tensile strength. We obtained intact interface and high mechanical strength for all three couples at the rotational speed ranges from 600-1000 rpm and transverse speed from 40-80 mm/min.
International Journal of Materials and Product Technology, 2018
The present review paper focuses on the various researches done in joining of aluminium and copper by friction stir welding (FSW). Being a solid state process, FSW has proven to efficiently join aluminium and copper which is extensively used in power generation, electrical and electronic industry. However, it is a challenge to achieve a good quality welded joint of aluminium and copper due to the difference in properties of both the materials. The present review paper comprehensively reports the study of microstructure and its evolution during the process. Also, an assessment of the formation of different intermetallic compounds (IMCs) during the process and the effect of various process parameters like rotational speed, tool traverse speed, the arrangement of base materials, offset and tool geometry on the IMCs and microstructure evolution is given.
Purpose: Friction stir welding (FSW) is a relatively new solid state joining process that uses a non-consumable tool to join two different material without melting the workpiece material. Friction stir welding (FSW) was developed for microstructural modification of metallic material. This review article provides an overview of effect of FSW/FSP mechanism responsible for the formation of weld, microstructure refinement, wear of FSW tool and mechanical properties. This review conclude with recommendations for future research direction. Design/methodology/approach: Heat is generated by friction between the rotating tool and the workpiece material. This joining process is energy efficient, environment friendly and versatile.