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

Abstract

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.

Characterization of Dissimilar Al-Cu BFSW Welds; Interfacial Microstructure, Flow Mechanism and Intermetallics Formation

“…Moreover, micro-hardness of the weld nugget is also affected by the IMCs. Commonly found IMCs in Al-Cu FSW joints are CuAl2, Cu9Al4, Cu3Al and CuAl, Al2Cu and 1 -Al4Cu9 phases were found to be formed in an Al 6082-T6/ Cu FSW [42].…”

Influence of Process Parameters on Joint Characteristics in Friction Stir Welding of Al/Cu Dissimilar Materials for Lithium-ion Battery

“…However, most previous studies have performed FSW lap joining of dissimilar materials, such as Al-Mg [4], Al-Steel [5], Al-Ti [6], and Fe-Mg [7]. Some researchers have studied the FSW of Al-Cu dissimilar joints, but their paper deals with high-strength aluminum alloys, such as aluminum 2XXX [8], 5XXX [9], and 6XXX [10] series.…”

Study of the Correlation between the Process Parameters and the Mechanical Characteristics of the Aluminum Sheets Welded by the FSW Process

“…Friction stir welding (FSW) is a relatively new welding process that may have significant advantages compared to the fusion processes as follow: joining of conventionally non-fusion weldable alloys, reduced distortion and improved mechanical properties of weldable alloys joints due to the pure solid-state joining of metals (Chen et al, 2003). In this process, the heat is originally derived from the friction between the welding tool (including the shoulder and the probe) and the welded material, which causes the welded material to soften at a temperature less than its melting point (Threadgill et al, 2009;Mishra et al, 2005;Xue et al, 2011;Barekatain et al, 2014;Wiedenhoft et al, 2018;Naik et al, 2013). FSW can also assemble different joint configurations, such as lap, butt, and T-joints, of which the lap joints are widely applied in vehicle and aircraft design and manufacturing.…”