Influence of plate position, tool offset and tool rotational speed on mechanical properties and microstructures of dissimilar Al/Cu friction stir welding joints

Sahu, Priyadarshi Soumyaranjan; Pal, Sukhomay; Pal, Surjya K.; Jain, Rahul

doi:10.1016/j.jmatprotec.2016.04.014

Cited by 138 publications

(79 citation statements)

References 24 publications

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“…9b represents around 50% Al and Cu which is also quite similar to the XRD analysis. It indicates that the main phase constituent in this area is AlCu [13,21] which was also detected by the XRD analysis. But in case of E4 the fracture occurs at Cu side as represented in the Fig.…”

Section: Fractography Of Fractured Surface and Edx Analysissupporting

confidence: 54%

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Effect of solid solution phase constitution on dissimilar Al/Cu FSW using Zn as an alloying element at the joint interface

2019

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The effect of Al/Zn/Cu binary and ternary solid solution phase constituents on metallurgical and mechanical properties of Al/Cu dissimilar friction stir welding using Zn as an alloying element was investigated. Because of Zn interlayer material binary intermetallic compounds (IMCs) such as AlCu, Al 2 Cu, Al .71 Zn .29 , CuZn 5 and ternary IMCs such as Al 4.2 Cu 3.2 Zn .7 are formed. These solid solution alloying phase constituents improved the weld properties of the joint. The tensile strength was enhanced by 13% for Zn alloying specimens compared with non-alloyed weld specimen and 104% of the Al base material due to the formation of thin and controlled IMCs and solid solution phase constitution strengthening as well as Orowan strengthening. The fractured surface with Zn alloying element suggested combination of ductile-brittle fracture and indicated transgranular failure. Micro-hardness with Zn alloying specimen is higher compared to the non-alloyed specimen for the existence of different IMCs at the stir-zone. The mapping analysis indicated that the thickness of the IMCs with Zn alloying was at micro-meter level. Phase constituent revealed that thin continuous and uniformly distributed binary and ternary phases are beneficial for the enhancement of mechanical and metallurgical qualities. Macrostructural views revealed variation in IMCs flows at non-alloyed and Zn alloying cases. Different weld zone reflected grain variations and finer grain at the weld nugget due to the nucleating effect of Zn interlayer.

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Section: Fractography Of Fractured Surface and Edx Analysissupporting

confidence: 54%

“…The Al and Cu workpieces were put on the retreating and the advancing side of the rotating tool, respectively. An optimized tool offset of 1.5 mm was given towards the soft Al alloy for proper weld qualities [13]. The tool material used is H13 steel and fabricated cylindrical pin of 6 mm diameter, 25 mm shoulder diameter and 3.5 mm pin length.…”

Section: Methodsmentioning

confidence: 99%

Effect of solid solution phase constitution on dissimilar Al/Cu FSW using Zn as an alloying element at the joint interface

2019

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“…Thus, increasing attention has been given to solid state welding methods, such as friction stir welding (FSW) and ultrasonic spot welding (USW). It is demonstrated that FSW has great potential in the production of high-performance Cu/Al joints due to the low processing temperature [5][6][7][8]. Compared to friction stir spot welding, in this method, a sound joint is produced by ultrasonic spot welding with a shorter bonding cycle [4,9,10].…”

Section: Introductionmentioning

confidence: 99%

Effects of Vibration Amplitude on Microstructure Evolution and Mechanical Strength of Ultrasonic Spot Welded Cu/Al Joints

Liu

Biao

Yang

2017

Metals

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Abstract:The effects of vibration amplitude on the interface reaction and mechanical strength of the Cu/Al joints were systematically investigated in ultrasonic spot welding (USW) experiments. The appropriate vibration amplitude (22.5 µm) was beneficial for obtaining a sound joint. The formation of the continuous intermetallic compounds (IMC) layer accelerated with a higher vibration amplitude. The lap shear tensile strength of the Cu/Al joints decreased when the thickness of the intermetallic layer was greater than 1 µm at various amplitudes. With the increase in welding time, a crack occurred in the copper side owing to the occurrence of the eutectic reaction, α-Al + θ → L, at the periphery of the nugget. The remarkable decline of ultrasonic power curves occurred at various amplitude levels upon the formation of a crack in the copper side.

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“…Unlike other welding processes, this technique is characterized by the absence of melting, low temperature and low heat input [11,12]. These properties give rise to the wide application of FSW in dissimilar welding [13][14][15][16][17]. Much work has been carried out on the FSW of Al to Mg in butt and lap joints [18][19][20][21].…”

Section: Introductionmentioning

confidence: 99%

The effect of changing chemical composition on dissimilar Mg/Al friction stir welded butt joints using zinc interlayer

Abdollah-zadeh

Shokuhfar

Cabrera

et al. 2018

Journal of Manufacturing Processes

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In this study, solid state joining technology of friction stir welding (FSW) was carried out for Al and Mg butt joints.To improve the microstructural characteristics of the banded structure zone, before to the FSW process, a Zn interlayer was also inserted in the butt joints. Optimal conditions for friction stir welding were obtained using a combination of two travel speeds (25 and 35 mm/min) and three rotation speeds (550, 600 and 650 rpm). Mg-Zn and Mg-Al-Zn IMCs, Al solid solution and residual Zn were the most common phases in the stirred zone, eliminating Al-Mg intermetallic formation. The joint fabricated at 35 mm/min and 600 rpm, in which tensile strength of the weld improved from 141 to 175 MPa and an elongation from 0.7 to 1.9 was achieved, gave the maximum mechanical properties compared with the Zn free sample FSWed under identical conditions. The fracture micrographs were compatible with the corresponding ductility results and the fracture surfaces of Zn added samples possessed a fine texture combining brittle and ductile fracture features. Meanwhile, the hardness level was lower than that of the Zn free sample because of the change in the IMCs composition of the Zn added samples.

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Influence of plate position, tool offset and tool rotational speed on mechanical properties and microstructures of dissimilar Al/Cu friction stir welding joints

Cited by 138 publications

References 24 publications

Effect of solid solution phase constitution on dissimilar Al/Cu FSW using Zn as an alloying element at the joint interface

Effect of solid solution phase constitution on dissimilar Al/Cu FSW using Zn as an alloying element at the joint interface

Effects of Vibration Amplitude on Microstructure Evolution and Mechanical Strength of Ultrasonic Spot Welded Cu/Al Joints

The effect of changing chemical composition on dissimilar Mg/Al friction stir welded butt joints using zinc interlayer

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