Friction stir welding of aluminum to copper—An overview

Sharma, Nidhi; Khan, Zahid A.; Siddiquee, Arshad Noor

doi:10.1016/s1003-6326(17)60238-3

Cited by 107 publications

(58 citation statements)

References 91 publications

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“…By contrast, a high rotational speed of 1320 r/min with turbulence stirring increased the flow of plasticised Al material into the Cu alloy, thereby causing the formation of microdefects also mentioned by Bisadi et al [44]. Moreover, severe stirring at high rotational speed led to grain coarsening, resulting in the reduction in σ s and σ p values [45]. Notably, the use of excessively high or low welding speeds significantly affected the Al-Cu interface bonding.…”

Section: Effect Of Friction Stir-welding (Fsw) Process Parameters On mentioning

confidence: 93%

Effect of Process Parameters on Interfacial Bonding Properties of Aluminium–Copper Clad Sheet Processed by Multi-Pass Friction Stir-Welding Technique

Osman

Sajuri

Baghdadi

et al. 2019

Metals

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In this study, continuous multi-pass friction stir welding was used to clad dissimilar AA6061 aluminium (Al) and C2801P copper (Cu) alloy materials. The empirical relationships between three process parameters and two-factor responses of Al–Cu clad joints were evaluated. Mathematical models were generated using regression analysis to predict the variation in tensile shear and peel load of the cladded joints. The sufficiency of the developed model was validated by analysis of variance (ANOVA), and the multi-criterion optimisation of factor responses was carried out via the response surface method. Results showed the formation of mechanical interlocking at the cladded interface and the development of a thin metallurgical bonding layer consisting of Al alloy content (8–21%), which greatly affected the quality of the Al–Cu joint interface. Moreover, the increase in shoulder overlap ratio, welding speed and tool rotational speed improved the shear and peel strength up to a certain range before gradually declining. The optimised process parameters for the cladded Al–Cu were obtained at a rotational speed of 986 r/min, welding speed of 8.6 mm/min and shoulder overlap ratio of 35%. The cladded Al–Cu generated a shear strength of 5850 kPa and peel strength of 750 kPa with an overall desirability function of 0.94.

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Section: Effect Of Friction Stir-welding (Fsw) Process Parameters On mentioning

confidence: 93%

Effect of Process Parameters on Interfacial Bonding Properties of Aluminium–Copper Clad Sheet Processed by Multi-Pass Friction Stir-Welding Technique

Osman

Sajuri

Baghdadi

et al. 2019

Metals

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“…Aluminium to copper dissimilar welds are a highly applicable hybrid joint, necessary for high-tech industrial applications, where it is needed to meet specific ductility or low-weight requirements, as well as providing thermal and/or electrical conductivity, with corrosion resistance [1]. Examples of high-performance Al-Cu welds used include electronic industries, transportation vehicles, energy industries, and aerospace components [2].…”

Section: Introductionmentioning

confidence: 99%

Characterization of Dissimilar Al-Cu BFSW Welds; Interfacial Microstructure, Flow Mechanism and Intermetallics Formation

Tamadon

Abdali

Pons

et al. 2020

Advances in Materials Science

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The purpose of this study is to elucidate the flow features of the dissimilar Al-Cu welded plates. The welding method used is Bobbin Friction Stir Welding (BFSW), and the joint is between two dissimilar materials, aluminium alloy (AA6082-T6) and pure copper. Weld samples were cut from along the weld line, and the cross-sections were polished and observed under an optical microscope (OM). Particular regions of interest were examined under a scanning electron microscope (SEM) and analysed with Energy Dispersive X-ray Spectroscopy (EDS) using the AZtec software from Oxford Instruments. The results and images attained were compared to other similar studies. The reason for fracture was mainly attributed to the welding parameters used; a higher rotational speed may be required to achieve a successful BFSW between these two materials. The impact of welding parameters on the Al-Cu flow bonding and evolution of the intermetallic compounds were identified by studying the interfacial microstructure at the location of the tool action. The work makes an original contribution to identifying the solid-phase hybrid bonding in Al-Cu joints to improve the understanding of the flow behaviours during the BFSW welding process. The microstructural evolution of the dissimilar weld has made it possible to develop a physical model proposed for the flow failure mechanism.

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“…The dissimilar alloy welding process depicts its effects on the mechanical strength of the welded specimen. The effect of this welding process on micro structure has been studied along with the formation of intermetallic region at the weld joint [2]. For any type welding, the formation of intermetallic compounds is a crucial element.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Weld Joint: Cupro – Nickel with Aluminium 5083

Dominic*¹,

Krishnakumar²,

Saravanan³

2019

IJRTE

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Cupro-Nickel and Aluminium alloy to their series, Al 5083 and 70Cu30Ni are the critical alloys in ship building mainly in piping section. Due to the reason of having a huge difference in their physical and chemical properties, obtaining a good bonding between them by welding is rather a tough job. The welding was conducted by giving waviness to the torch and allowing the molten pool of Cu-Ni to flow towards the Al 5083 and thereby joining them without melting the aluminium. The microstructure was studied by welding plain plates as well as Nickel coated plates. The microstructural study showed that there is a good bonding between the two alloys. The SEM imaging confirms the bonding of the two alloys at the welded region. The elemental composition of the weld joint was found by EDS analysis. The formation of intermetallics was confirmed by XRD analysis. Then the hardness at the weld joint was studied. The hardness value obtained from testing was promising and there with showing a good properties at the welded joint. The Ni coated welded alloys showed significant and improved results when comparing with the non-nickel plated metal plates. With the hardness value varying from the non Ni coated plates was found to be high compared to the hardness value of the Al and Cu-Ni alloy. But the further study showed that that hardness value adds much to the weld stability by the formation of good bonds between the alloys and that of the intermetallics formed. The impact tests conducted on the welded specimen shows good results with regards to the comparison with the impact strength of 70Cu30Ni and the energy absorbed by the welded specimen. The results showed that welding is possible between these alloys and the nickel coated alloys shows better results in strength and bonding than non- nickel coated alloys. This study also confirms that GTAW can be very effective in joining these dissimilar alloys.

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Friction stir welding of aluminum to copper—An overview

Cited by 107 publications

References 91 publications

Effect of Process Parameters on Interfacial Bonding Properties of Aluminium–Copper Clad Sheet Processed by Multi-Pass Friction Stir-Welding Technique

Effect of Process Parameters on Interfacial Bonding Properties of Aluminium–Copper Clad Sheet Processed by Multi-Pass Friction Stir-Welding Technique

Characterization of Dissimilar Al-Cu BFSW Welds; Interfacial Microstructure, Flow Mechanism and Intermetallics Formation

Evaluation of Weld Joint: Cupro – Nickel with Aluminium 5083

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