Effect of a Zinc Interlayer on a Cu/Al Lap Joint in Ultrasound-Assisted Friction Stir Welding

Chen, Shujin; Wang, Di; Li, Ruifeng; Liu, Bin; Wang, Jianxin

doi:10.1007/s11665-019-04244-3

Cited by 12 publications

(16 citation statements)

References 25 publications

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“…When Al-Cu is welded without interlayer either through butt configuration or lap configuration, the IMCs formed are AlCu, 2,7,11,16,20,22,26 Al 2 Cu, 2,7,11,16,[20][21][22]26,110,111,113,114 Al 2 Cu 3 , 7,11,20,22,112 Al 3 Cu 4 , 20,22 and Al 4 Cu 9 . 7,11,12,16,20,22,26,109,[111][112][113][114] Mechanical properties of FSWed Al-Cu joints Sahu et al investigated the hardness of dissimilar friction stir welded Al-Cu joints.…”

Section: Microstructures and Imcsmentioning

confidence: 99%

“…54 The majority of research suggests that brittle IMC development may be avoided, and joint strength will be successfully increased by incorporating third materials like Cu, zinc, nickel, vanadium, Ag, alloys, and the multi-interlayer as an intermediary interlayer that stop the BMs from coming into direct contact with one another. 21,29,34,38…”

Section: Fswed Al-cu Joints With Interlayermentioning

confidence: 99%

“…Large number of hard, brittle, low strength, and high electrical resistance intermetallics are produced in different weld zones during the joining of Al and Cu. [19][20][21][22][23][24][25][26][27][28] Al and Cu joints are not successfully joined by fusion welding processes due to solidification and liquefaction cracking and the production of hard, brittle IMCs [29][30][31] and hence it results in weld defects. 1,2,10,20,21 Diffusion welding, ultrasonic welding, explosive welding, cold rolling, friction welding, and friction stir welding (FSW) are solid-state welding methods that can be used to avoid these issues and create beneficial joints.…”

Section: Introductionmentioning

confidence: 99%

“…[19][20][21][22][23][24][25][26][27][28] Al and Cu joints are not successfully joined by fusion welding processes due to solidification and liquefaction cracking and the production of hard, brittle IMCs [29][30][31] and hence it results in weld defects. 1,2,10,20,21 Diffusion welding, ultrasonic welding, explosive welding, cold rolling, friction welding, and friction stir welding (FSW) are solid-state welding methods that can be used to avoid these issues and create beneficial joints. In 1991, Thomas et al 13 of the Welding Institute (TWI), London, UK, patented an advanced solid-state joining technique called FSW that offered entirely altered physical, chemical, and mechanical properties for the joints of high chemical affinity dissimilar materials like Al and Cu.…”

Section: Introductionmentioning

confidence: 99%

“…The majority of research suggests that brittle IMC formation can be prevented and joint strength will effectively be improved by preventing direct contact between the BMs by inserting third materials such as Cu, zinc, nickel, vanadium, silver (Ag), alloys, and the multi-interlayer as an intermediate interlayer. 21,29,34,38 Researchers have conducted detailed reviews on the role of FSW tool, tool geometry, process parameters, welding strategy, and alternative technology in attaining sound Al-Cu friction stir welded joints. 1,13,19,33,[38][39][40][41][42][43] Their review has also reviewed and highlighted mechanical characterization, microstructural evaluation, welding defects, and IMCs formed in Al-Cu FSWed joints.…”

Section: Introductionmentioning

confidence: 99%

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A review on recent development in aluminium-copper friction stir welding

Payak

Paulraj

Roy

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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Aluminium (Al) and copper (Cu) are widely employed in the industry due to their significant corrosion resistance and electrical conductive properties. The simultaneous requirement of different special properties has increased the trend of joining of Al and Cu. The joining of dissimilar materials has arisen as a new challenge in the research field in the past decade. Friction stir welding (FSW) is a very worthy process to join metals that aren't the same. This article delves into the intricacies of FSW to join compatible metals such as Al and Cu. The various parameters of FSW, namely tool design, tool pin offset, rotation speed, welding speed, tilt angle, and different types of welding joints, are highlighted in this article. It also goes through the different types of defects, microstructures, and intermetallic compounds (IMCs) that are formed during Al-Cu FSW. The electrical behavior and corrosion behavior of the weld zone in Al-Cu FSWed joints were also reviewed. Role of interlayer in some emphasis was also given to form effective joints.

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Section: Microstructures and Imcsmentioning

confidence: 99%

Section: Fswed Al-cu Joints With Interlayermentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

A review on recent development in aluminium-copper friction stir welding

Payak

Paulraj

Roy

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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Microstructural and mechanical characteristics of friction stir welded Al6101/C11000 joints with zinc and silver interlayer

Payak

Paulraj

Roy

et al. 2023

Int J Adv Manuf Technol

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This manuscript presents the microstructure, and mechanical analysis of 3 mm thick Al 6101 (aluminum alloy) and C11000 (Cu alloy) plates Friction Stir Welded joints with and without Silver and Zinc interlayers. The tool used to make joints is made of H 13 steel, having a shoulder with 18 mm diameter and a taper pin with 4 mm tip and 6 mm root diameter. The quality of welded joints has been inspected using tensile testing, micro-hardness tests, scanning electron microscopy, and energy dispersive X-ray analysis. Microstructural studies clari ed the ow variation of constituents with and without interlayer.Incorporation of a Silver and Zinc interlayer between the joining surface of aluminum and copper alloy decreased the generation of brittle intermetallics. The joint made with hybrid interlayers (Silver and Zinc) has the highest tensile strength with complete ductile fracture compared to the other joints tested.

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