Due to physical properties like high thermal and electrical conductivity, joining of copper is of special interest in steelmaking or electrical industry. Unfortunately, joining of thick-walled copper components using electron beam welding (EBW) tends to welding defects like insufficient root formation or varying penetration depth. In previous investigations, Cu-DHP (deoxidised high phosphorus copper) plates were successfully joined by EBW utilising a CuSn6 sheet as filler material. The investigation resulted in a stable EBW parameter window. Nevertheless, using CuSn6 sheets lead to challenges concerning joint preparations, and is not usable for arbitrary weld configurations. To meet these challenges, atmospheric plasma spraying (APS) is used to apply a thin interlayer in the welding zone and substitute the CuSn6 sheet filler metal. This continuative work includes further improvements of the main EBW parameters and uses APS as a new approach for filler metal deposition. Furthermore, determining and enhancing the service properties of the copper joints is of main interest and reported here.
TiO2 micro powder was deposited onto an aluminum substrate by atmospheric plasma spraying resulting in 200 μm thick coatings. These coatings were characterized, whereby typical layer properties like porosity, layer thickness and hardness were investigated. Subsequently, a thermo-mechanical load was applied to the TiO2 coating by friction stir processing. This testing procedure indicates several advantages. First, specific load cycles can be applied at high accuracy using specific parameter sets. Secondly, different tool geometries can be used for testing, resulting in countless possible load cases and testing scenarios. As a result, the thermal properties of the TiO2 coating were investigated and compared as a function of a stepwise increased testing load. To complete the experimental results, a numerical simulation of the testing process was set up to estimate the transient heat flow of the TiO2 coating during friction stir processing.
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