Cooling-assist friction stir welding: A case study on AA6068 aluminum alloy and copper joint

Abstract

This study evaluates the impact of cooling-assist friction stir welding (CA-FSW) tool rotational and traverse velocities on the bonding quality of Al-Cu-Mg and copper lap joints. A modified computational fluid dynamics (CFD) technique analyzes heat generation and distribution during dissimilar CA-FSW joints between AA6068 alloy and copper. The relationship between CA-FSW tool velocities and metallurgical properties of the final joint is assessed. Simulation results provide insights into metallurgical phenomena during the CA-FSW process. Findings reveal greater plastic deformation and heat generation on the AA6068 aluminum alloy side due to raw material placement, resulting in more significant microstructure changes in AA6068 aluminum alloy compared to copper. Increased heat generation leads to higher copper-rich intermetallic compound (IMC) formation, resulting in increased hardness of the stir zone at the base metals’ interface.

AA5754–Al2O3 Nanocomposite Prepared by Friction Stir Processing: Microstructural Evolution and Mechanical Performance

“…The evaluation of sample surfaces constituted a pivotal aspect of this study, providing crucial insights into the effects of FSP conditions and the incorporation of nanopowder on surface characteristics [22]. Optical images of all the samples were meticulously examined, offering visual representations of surface features as depicted in Figure 5.…”