Effect of Friction Stir Welding Parameters on the Mechanical and Microstructure Properties of the Al-Cu Butt Joint

Abstract

Friction Stir Welding (FSW) is a solid-state welding process used for welding similar and dissimilar materials. FSW is especially suitable to join sheet Al alloys, and this technique allows different material couples to be welded continuously. In this study, 1050 Al alloys and commercially pure Cu were produced at three different tool rotation speeds (630, 1330, 2440 rpm) and three different tool traverse speeds (20, 30, 50 mm/min) with four different tool position (0, 1, 1.5, 2 mm) by friction stir welding. The influence of the welding parameters on the microstructure and mechanical properties of the joints was investigated. Tensile and bending tests and microhardness measurements were used to determine the mechanical properties. The microstructures of the weld zone were investigated by optical microscope and scanning electron microscope (SEM) and were analyzed in an energy dispersed spectrometer (EDS). Intermetallic phases were detected based on the X-ray diffraction (XRD) analysis results that evaluated the formation of phases in the weld zone. When the welding performance of the friction stir welded butt joints was evaluated, the maximum value obtained was 89.55% with a 1330 rpm tool rotational speed, 20 mm/min traverse speed and a 1 mm tool position configuration. The higher tensile strength is attributed to the dispersion strengthening of the fine Cu particles distributed over the Al material in the stir zone region.

Study of the Microstructure Evolution and Properties Response of a Friction-Stir-Welded Copper-Chromium-Zirconium Alloy

“…The FSW process is proved process is proved to be a perfect choice for copper alloys [7,[15][16][17][18], and it has been successfully implemented in industrial applications [19,20]. However, little research has been carried out on the CuCrZr alloy fabricated by FSW.…”

Microstructure and Mechanical Properties of Ultrasonic Welded Joint of 1060 Aluminum Alloy and T2 Pure Copper

“…Furthermore, the Cu/Al dissimilar metal joints are extensively applied in the electricity, packaging, ground, and space vehicles industry due to desired thermal and electrical conductivity [5]. Lee et al [6] have researched the electrical and mechanical properties of friction welded Cu/Al bimetal joints.…”

Influence of Process Parameters on the Vertical Forces Generated during Friction Stir Welding of AA6082-T6 and on the Mechanical Properties of the Joints

“…Furthermore, under suitable process conditions, FSW can allow the obtaining of a microstructure able to provide mechanical properties much higher than those of most fusion welding processes and formability levels so high that post-welding forming processes of welded blanks can be performed. Because of these advantages, FSW can be very useful both in joining materials with poor weldability or that are un-weldable, such as aluminium and magnesium alloys, and in the obtaining of joints characterised by high efficiency [1][2][3][4][5][6][7][8][9][10][11].…”