Achieving High-Quality Aluminum to Copper Dissimilar Metals Joint via Friction Stir Double-Riveting Welding

Ji, Shude; Cui, Xiao; Ma, Lin; Liu, Hua; Zuo, Yingying; Zhang, Zhiqing

doi:10.1007/s40195-022-01512-5

Cited by 37 publications

(8 citation statements)

References 43 publications

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“…Combined with the steel BM having a strength much higher than the aluminum BM, the plunging movement of the tool pin makes the materials in the lower plate contacting the tool pin flow upwards and then into the upper aluminum alloy due to the minimum resistance law [39,40], thereby leading to the concave-down shape and hook structure at the lap interface (Figure 2). Similar morphology features of the lap interface are also reported by some researchers such as Ji et al [10], Chen et al [18], Liu et al [30], and so on. In order to more thoroughly analyze the formation features at the lap interface, typical regions are enlarged and displayed in Figures 3 and 4.…”

Section: Joint Cross-sectionsupporting

confidence: 87%

“…From the above-mentioned welding procedure, it is known that the tool pin plunges through the upper aluminum plate and then 0.05 mm into the lower steel plate. Ji et al [10] reported that the region with high temperature during the FSW process was mainly located near the welding tool, and the temperature decreased with increasing the distance away from the welding tool. Because the melting point of steel is higher than that of aluminum alloy, the region with high temperature during welding is mainly located at the lap interface between the upper aluminum and lower steel plates [18,38].…”

Section: Joint Cross-sectionmentioning

confidence: 99%

“…Friction stir welding (FSW) is a relatively new solid-state welding technology that has low heat input during the welding process compared with traditional fusion welding and brazing. Thus, FSW technology effectively suppresses the formation of IMCs at the Al/steel lap interface and avoids defects such as inclusions and porosities [9,10]. Currently, FSW technology has become one of the important methods for fabricating the high-strength Al/steel joint [11].…”

Section: Introductionmentioning

confidence: 99%

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Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Han,

Yu,

Yan

et al. 2024

Metals

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Achieving high-strength welding joint of aluminum to steel is a highly pressing and challenging task in the manufacturing industries, and friction stir lap welding (FSLW) has advantages for joining these two metals. To further heighten the strength of dissimilar aluminum and steel metals (Al/steel) FSLW joint, the ultrasonic-assisted FSLW (UAFSLW) process was used, and the upper 2024-T4 aluminum alloy and the lower 304 stainless steel were chosen as research object. The results show that the addition of ultrasound eliminates the micro pores, changes the aluminum-rich intermetallic compounds (IMCs) into the iron-rich IMCs and enhances the micro and macro mechanical interlocking structures along the Al/steel lap interface. Under the rational IMCs layer thickness lower than 1.5 μm, the UAFSLW joint has the failure load higher than the traditional FSLW joint. The maximum failure load of UAFSLW joint reaches 7.06 kN, and the loading capacity of this joint is higher than that of reported Al/steel traditional FSLW joint. The UAFSLW process is an effective way to fabricate the high-strength Al/steel lap joint.

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Section: Joint Cross-sectionsupporting

confidence: 87%

Section: Joint Cross-sectionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Han,

Yu,

Yan

et al. 2024

Metals

Self Cite

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“…16,17 Thus, aluminium to copper dissimilar metals joint via modified version of FSW, friction stir double-riveting welding (FSDRW) was proposed with superior mechanical interlocking along Al/Cu interface. 18 This friction stirred procedures have also been used for the strengthening and joining by plastic deformation in polymers and polymeric materials. 19 The tool pin extruded keyhole size should be less to improve the weld mechanical performance and weld morphology of acrylonitrile butadiene styrene (ABS).…”

Section: Introductionmentioning

confidence: 99%

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Pattanaik,

Nayak,

Bisoyi

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Friction stir processing procedures are often found to be an alternative choice for the joining of thermoplastic polymers without melting the base materials. In recent years, dissimilar metallic to thermoplastic assemblies are highly used in aerospace and automotive industries as mechanical fastener or fusion welding techniques are rather inadequate for extreme discrepancy in thermal properties. The present work addresses the feasibility of friction stirred spot welding for non-ferrous aluminium (Al 6061) to polycarbonate using taper cylindrical tool of hardened H13 steel along with machine integrated axial thrust and stirring torque signals. The real-time positional and axial velocity of the rotating tool has been acquired to distinguish between plunging and dwelling stage. The process stability that is, the deviation of thrust-torque in respective phases was processed. The interaction of plunge depth and dwell time on tool pin assisted keyhole with associated material expulsion for different tool revolving speed was established. The weld mechanical behaviour has been scanned using load versus elongation diagram with associated weld pair interface. Lastly, sensors’ based process monitoring extended to weld quality prediction have been made using various significant features of thrust-torque-velocity based approaches. The tool spinning speed followed by dwell time was found to be important on weld quality index. The joint efficiency was significantly upgraded (more than 60%) at intermediate dwell time (40 s) with low tool plunging (0.3 mm) or reversed parametric setting at high tool revolving speed (2500 rpm) due to substantial reduction in axial thrust with higher stirring torque. The local deviation in thrust-torque during plunging was equally responsible with global mean thrust-torque in dwelling to dictate the joint strength and the weld ductility. The material stirring torque was better indicator of weld shear strength while pin assisted slot size highly correlated with tool thrust though tool plunging speed was highly crucial.

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“…At present, a large number of experimental studies have been conducted for Al alloys 4,5 ,Al-Ti alloys, 6 Al-steel alloys, 7 Al-Cu alloys, 8 and Al-Mg dissimilar alloys. [9][10][11][12] using stir friction welding technology.…”

Section: Introductionmentioning

confidence: 99%

Influence of secondary welding on microstructure and mechanical properties of friction stir welded joints of AA6061 and AZ31B alloys

Hu,

Deng,

Zeng

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Butt joints made of 6061-T6 Al and AZ31B Mg dissimilar materials were fabricated using friction stir welding (FSW). Three welding techniques were used in the experimental process: method 1-Mg on the advancing side (AS), method 2-(Al on the AS), and method 3-(Mg was placed on the AS for the first welding experiment, and then the plate was rotated horizontally by 180° so that Al was placed on the AS for the second welding). Focus on the comparative analysis of the second welding and primary welding on the microstructure and mechanical properties of the joint. The results show that the joints with the secondary welding method have the characteristics of onion rings in the stirred zone (SZ), where there is a serious mixture of Al and Mg, and the degree of mechanical bonding is significantly increased. At the same time, the enhanced mechanical effect of secondary welding on the weld led to a change in the microhardness of the SZ. In the tensile tests, the strength of the secondary welded joint was increased to 120 MPa compared to the primary welded joint strength of 89 and 95 MPa due to the increase in the degree of mechanical bonding of the secondary welded joints and the increase in the level of mixing of plastic materials in the SZ. In addition, the type of fracture of the joint in all three welding methods is a brittle fracture.

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Achieving High-Quality Aluminum to Copper Dissimilar Metals Joint via Friction Stir Double-Riveting Welding

Cited by 37 publications

References 43 publications

Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Influence of secondary welding on microstructure and mechanical properties of friction stir welded joints of AA6061 and AZ31B alloys

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