Friction stir butt welding of Al-Cu bilayer laminated composites: analysis of force, torque, and temperature

Beygi, R.; Kazeminezhad, M.; Mehrizi, M. Zarezadeh; B, G. Eisaabadi; Loureiro, A.

doi:10.1007/s00170-016-8778-y

Cited by 24 publications

(9 citation statements)

References 23 publications

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“…Axial force is another important process parameter that affects the joint produced through FSW. Beygi et al 86 studied friction stir butt welding of Al–Cu bilayer laminated composites and found the surface contact conditions between the laminated sheet and the tool shoulder play an important role in torque and force development and therefore material flow behavior. Good tensile strength of the weld joint is achieved using sufficient axial force.…”

Section: Mechanical Properties Of Fs Welded Amc Jointsmentioning

confidence: 99%

Joining of aluminium matrix composites using friction stir welding: A review

Mir

Khan

Siddiquee

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Aluminium matrix composites are one of the most important classes of materials and have become a major focus of attention in aerospace, aeronautical, defense, and automotive industries. Aluminium matrix composites when compared to conventional alloys offer various promising properties like excellent strength-to-weight ratio, higher stiffness, lower coefficient of thermal expansion, better dimensional stability, and tribological behavior. The properties of aluminium matrix composites are highly influenced by the appropriate selection of metal matrix, processing routes, and reinforcement. Various ceramic particles (oxides, carbides, nitrides, borides, etc.) are used as reinforcements for aluminium matrix composites. Significantly different properties may be obtained using various reinforced particles and matrix material, which makes it difficult for the traditional fusion welding techniques to meet the joining requirements of these composites and is restricted to certain grades of materials. Solid-state welding process offers greater advantages over the conventional fusion welding. As a solid-state joining process, friction stir welding has proven to be a better and promising technique for joining aluminium matrix composites. However, it is still subjected to various challenges to join aluminium matrix composites even with considerable progress has been made in recent years. The current review provides an overview of state-of-the-art of friction stir welding of aluminium matrix composite materials. Specific attention and critical assessment have been given to weldability, the macrostructure and microstructure of aluminium matrix composite joints, mechanical properties of joints, fractography, and the wear of friction stir welding tool during welding of aluminium matrix composite. Furthermore, the various existing challenges of friction stir welding of aluminium matrix composites are summarized and the recommendations for future research are proposed.

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Section: Mechanical Properties Of Fs Welded Amc Jointsmentioning

confidence: 99%

Joining of aluminium matrix composites using friction stir welding: A review

Mir

Khan

Siddiquee

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…Previously published works dealing with Al plus Cu composites mostly focused on their design [27,28], fabrication methods [14,29], deformation behaviour [30], structure characterization [31][32][33], and determination of mechanical properties [34,35]. Several studies also dealt with basic characterization of their electric properties [13].…”

Section: Introductionmentioning

confidence: 99%

Influence of (Sub) Structure Development within Rotary Swaged Al–Cu Clad Conductors on Skin Effect during Transfer of Alternating Current

et al. 2022

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The nature of alternating current transfer via metallic materials is specific, since the current density tends to be inhomogeneous across the cross-section of the conductor and the skin effect tends to occur. However, the influence of this effect on the behaviour of the conductor can be optimized via the design and fabrication procedures. The study presents innovative design of an Al–Cu clad conductor, which is supposed to affect favourably the influence of the skin effect. The clad conductors of various diameters (20 mm, 15 mm, and 10 mm) were fabricated via rotary swaging at room temperature, and their electric characteristics were subsequently examined both experimentally and via numerical simulations. Structure analyses performed to document the effects of the swaging technology on the development of substructure and characteristic structural features were carried out by scanning electron microscopy (electron backscatter diffraction analyses), and transmission electron microscopy. The results showed that the design of the composite has a favourable effect on decreasing the power losses during alternating current transfer and that the substructure development affected favourably the electric resistance of the conductor. The highest electric resistance was measured for the composite conductor with the diameter of 20 mm (1.8% increase compared to electric resistance during transfer of direct current). This value then decreased to 0.6%, and 0.1% after swaging down to the diameters of 15 mm, and 10 mm; the 10 mm composite featured the finest grains, partially restored structure, and texture randomization compared to the 20 mm and 15 mm composites. Manufacturing of the clad composite via rotary swaging imparted advantageous combinations of both the electric and mechanical properties, as swaging also introduced increased microhardness.

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“…Friction stir welding (FSW) is a promising technique for welding Al together with Cu, due to the good mechanical properties of the welded joint, no toxic fumes, no warping, and shielding issues, little distortion or shrinkage, and good welded joint appearance [9][10][11][12]. Friction stir welding is applied extensively in the automotive industry, especially vehicles of railway stations [13][14][15][16]. FSW is used to produce Al-Cu lap joints with excellent mechanical properties [17][18].…”

Section: Introductionmentioning

confidence: 99%

Optimum Rotational and Traverse Speeds of Al-Cu Joints Welded by FSW Based on the Formability of The Joint

Elmetwally

SaadAllah

Abd-Elhady

et al. 2021

Preprint

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Joining of aluminum to copper using Friction Stir Welding (FSW) is a primary manufacturing process that is in most applications followed by a secondary forming process. The objective of this research is to determine the optimum rotational and traverse speeds of Al-Cu Welded by FSW based on the formability of the joint. The formability and strength of Al-Cu joined by FSW are investigated under different operating conditions. Aluminum and copper blanks are welded at three different rotational speeds that are 910, 1280 and 1700 rpm, under three different traverse speeds, which are 16, 29 and 44 mm/min. The base metal used in this study is Aluminum (Al-1050) and copper under two conditions, i.e. as received and annealed. The mechanical properties of base metals and produced joints are evaluated by tensile and hardness tests. The Al-Cu joints by FSW are drawn into flangeless U and cup shapes in order to examine the formability of the joint. The maximum tensile load, punch load and forming index were obtained when Al is welded to annealed Cu at 1700 rpm and 16 mm/min, i.e. highest rotational and lowest traverse speeds, and that is due to the strain hardening of the joint. However, the ductility was maximum at 1280 rpm and 44 mm/min, i.e. moderate rotational and highest traverse speed. It can be concluded that if the Al-Cu joint by FSW will be used further in a forming process, it should be welded at a moderate rotational and high traverse speed in order to avoid strain hardening and improve the ductility of the joint.

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Friction stir butt welding of Al-Cu bilayer laminated composites: analysis of force, torque, and temperature

Cited by 24 publications

References 23 publications

Joining of aluminium matrix composites using friction stir welding: A review

Joining of aluminium matrix composites using friction stir welding: A review

Influence of (Sub) Structure Development within Rotary Swaged Al–Cu Clad Conductors on Skin Effect during Transfer of Alternating Current

Optimum Rotational and Traverse Speeds of Al-Cu Joints Welded by FSW Based on the Formability of The Joint

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