Recent research progress in friction stir welding of aluminium and copper dissimilar joint: a review

Isa, Mohammad; Moghadasi, Kaveh; Ariffin, Mohammad Ashraf; Raja, Sufian; Muhamad, Mohd Ridha; Yusof, Farazila; Jamaludin, Mohd Fadzil; Nukman, Y.; Karim, Mohd Sayuti Ab

doi:10.1016/j.jmrt.2021.09.037

Cited by 50 publications

(21 citation statements)

References 152 publications

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“…Dissimilar welding of metals is widely used in many industries since it provides safe structures with a combination of high mechanical properties and good cost [1]. Bimetals have been largely used in industry due to their good physical, chemical and mechanical properties, that cannot be obtained from a single material [2], [3].…”

Section: Introductionmentioning

confidence: 99%

“…Dissimilar welding of aluminum (Al) and copper (Cu) is largely used in the electric power, electronic and piping industries [1]. Many research works have investigated dissimilar joints of Al-Cu made by solid-state welding and fusion welding processes in order to optimize their properties and strength [1].Al-Cu joints made by a fusion welding process lead to the apparition of brittle intermetallic compounds (IMCs), which cause failure during cooling [4]. Furthermore, it was reported that the increase in electrical resistivity of the Al/Cu joints is associated with the formation of IMCs, which act as an additional heat source during the transmission of electric current.…”

Section: Introductionmentioning

confidence: 99%

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Solid-State Diffusion Welding of Commercial Aluminum Alloy with Pure Copper

Bedjaoui

Boumerzoug

Delaunois

2022

Int. J. Automot. Mech. Eng.

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The aim of this investigation is to study the effect of time and temperature on the solid-state diffusion welding of commercial aluminum alloy 2xxx series with a pure copper at 425°C, 475°C, 500°C, and 525°C during holding times from 15 min to 240 min. The main characterization techniques were optical microscopy, scanning electron microscopy, energy dispersive spectrometry, nanoindentation, microhardness measurements, and x-ray diffraction. Results showed that increasing the temperature and the holding time had an effect on the apparition of the intermetallics at the Al alloy/Cu interface. Five intermetallic phases namely Al2Cu, AlCu, Al3Cu4, Al2Cu3, and Al4Cu9 were identified at the interface. The mechanical properties of the welded joint Al/Cu alloy varied also with the time and temperature. The nanoindentation measurements showed that the highest values of hardness were recorded in AlCu and Al3Cu4 phases. The welding success of these dissimilar metals can be used for battery cables or to form heat exchanger plates for vehicles.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Solid-State Diffusion Welding of Commercial Aluminum Alloy with Pure Copper

Bedjaoui

Boumerzoug

Delaunois

2022

Int. J. Automot. Mech. Eng.

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“…As one of the solid-state joining techniques, friction stir welding (FSW) shows advantages over fusion welding in the applicability of materials and the operability of microstructural control [2,7]. Some welding defects like deformation, cracking and porosity can be avoided due to the low operating temperature of FSW [8].…”

Section: Introductionmentioning

confidence: 99%

Effect of water cooling on microstructure and mechanical properties of friction stir welded dissimilar 2A12/6061 aluminum alloys

Shi

Sun

Liu

et al. 2022

Mater. Res. Express

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In-process cooling has been reported beneficial to some friction stir welded (FSW) aluminum alloys. But the effect of water cooling (WC) on the performance of dissimilar joints is still unclear. This work studies the effects of process parameters and water cooling on the microstructure and mechanical properties of the dissimilar 2A12-T6/AA6061-T6 FSW joints. Two rotational speeds (1200 and 1500 rpm) and one welding speed (80 mm/min) were adopted. The macro/micro structural characteristics, microhardness distribution, tensile properties and fracture morphology have been investigated. The results show 2A12 on advancing side shows the higher plasticizing degree than 6061 during FSW. Cracks and tunnels are found in nugget zone (NZ) of 1200-80WC joint due to the poor fluidity of metals. The average grain size of NZ increases with the rotational speed and can be decreased by water cooling. For all of the joints, the lowest hardness positions locate in the heat affected zone of 6061. The effect of water cooling on hardness is found related to the nature of material and the rotational speed. The 1200-80 joint shows the best mechanical properties. Water cooling damages the mechanical properties of the 1200-80 joint by inducing void and crack defects. However, it enhances the strength of 1500-80 joint. The 1200-80WC joint fractures in NZ while others fracture in the positions with the lowest hardness. The fracture locations and morphology accord well with the microstructure, microhardness and tensile properties.

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“…Friction stir spot welding (FSSW) has been also used for fabrication of the lap joints made of aluminum and copper [10]. Siddharth et al [11] developed a processing window by selecting optimal FSSW parameter while joining of aluminum 5052 and copper C27200.…”

Section: Introductionmentioning

confidence: 99%

Lap joining of aluminum 5052 to copper by optimum friction stir spot welding process

Jadidi

Azhiri²,

Baghdadchi

et al. 2022

Int J Adv Manuf Technol

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In the present study, lap joints of dissimilar 5052 aluminum alloy and pure copper were fabricated by friction stir spot welding process. The work was aimed to find simultaneous effect of parameters such as tool rotary speed (1000, 1500, and 2000 rpm) and dwell time (5, 10, and 15 s) on lap shear force (LSF), hardness, and microstructure evolution. Also, statistical models of the quality characteristics were developed to understand which parameter has dominant effect on quality characteristics. Research findings showed that to obtain sound joints with high lap shear strength, tool rotary speed of 1500 rpm and dwell time of 15 s should be selected. It provides sufficient heat input for mechanical interlocking and prevents the formation of coarse and thick intermetallic compounds (IMCs) in the stir zone. On the other hand, to achieve maximum hardness, 2000 rpm tool rotary speed should be chosen to provide enough heat for formation of intermetallic compound and 10 s dwell time should be used to prevent enough time for microstructure refining. Moreover, from the statistical analyses, it was found that dwell time and tool speed are the significant factors for lap shear strength and hardness, respectively. In order to attain simultaneous maximum strength and hardness, tool speed of 1630 rpm and dwell time of 14 s should be used. In such condition, lap shear strength of 1980 N and hardness of 78 V are achieved with desirability of 86%.

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Recent research progress in friction stir welding of aluminium and copper dissimilar joint: a review

Cited by 50 publications

References 152 publications

Solid-State Diffusion Welding of Commercial Aluminum Alloy with Pure Copper

Solid-State Diffusion Welding of Commercial Aluminum Alloy with Pure Copper

Effect of water cooling on microstructure and mechanical properties of friction stir welded dissimilar 2A12/6061 aluminum alloys

Lap joining of aluminum 5052 to copper by optimum friction stir spot welding process

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