The dissimilar friction stir lap welding of 1A99 Al to pure Cu using Zn as filler metal with “pinless” tool configuration

Kuang, Binbin; Shen, Yifu; Chen, Wenhua; Yao, Xiyu; Xu, Haisheng; Gao, Jicheng; Zhang, Jingqing

doi:10.1016/j.matdes.2014.12.008

Cited by 80 publications

(41 citation statements)

References 23 publications

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“…A continuous brazing zone is successfully fabricated as the rotation speed is increased to 1200 rpm and 1500 rpm. The thickness of reaction layer reduces from 22 µm (see Figure 6a) to 17 µm (see Figure 10b) because more liquid has been squeezed out of the brazing zone, caused by increased heat input, which is agreement with that of the Al/Cu joint made by pinless FSW using a Zn filler [51]. Therefore, sufficient energy input is necessary to ensure the successful brazing of Al alloy and Al coating, which play a key role in determining the joining width of the joint.…”

Section: Parametric Studysupporting

confidence: 66%

Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

Zhou

Chen

et al. 2018

Metals

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Friction stir spot welding (FSSW) of Al to Ti alloys has broad applications in the aerospace and automobile industries, while its narrow joining area limits the improvement of mechanical properties of the joint. In the current study, an Al-coating was prepared on Ti6Al4V alloy by hot-dipping prior to joining, then a Zn interlayer was used during friction stir joining of as-coated Ti alloy to the 2014-Al alloy in a lap configuration to introduce a brazing zone out of the stir zone to increase the joining area. The microstructure of the joint was investigated, and the joint strength was compared with the traditional FSSW joint to confirm the advantages of this new process. Because of the increase of the joining area, the maximum fracture load of such joint is 110% higher than that of the traditional FSSW joint under the same welding parameters. The fracture load of these joints depends on the joining width, including the width of solid-state bonding region in stir zone and brazing region out of stir zone.optimize the mechanical properties of the joint [17][18][19][20][21]. Unavoidably, the traditional FSSW would leave a keyhole that reduces its bonding area [22]. Although some modified processes for FSSW, such as refill FSSW [23], flat FSSW [24], and short travel FSSW [25], have attempted to eliminate this visible keyhole, they are complicated and time-consuming owing to the rigorous welding conditions and/or complex tool design. Recently, friction stir brazing (FSSB) has been developed by using a pinless tool and adding brazing filler metal to induce metallurgical reaction at the interface with the aid of friction heat and forging pressure, instead of plastic flow [22]. This technique has successfully introduced a brazing zone in dissimilar joints of steel/Al [26], Cu/Al [27], and Al /Mg [28], while FSSB of Al and Ti alloys is yet to be reported.This work aims to find an effective approach to improve the joining area of the Al/Ti joint by combining FSSW and FSSB. Zinc (Zn) is an optional filler for FSSB of Al alloys as a result of its low melting point (420 • C), high solubility in Al, as well as absence of formation of IMCs in the Al-Zn alloying system [29][30][31][32]. During our preliminary study, a Zn interlayer was placed between the interface of 2014 Al and Ti6Al4V alloys for the FSSB process to determine their weldability. It was found that the high affinity of Ti towards oxygen led to the formation of non-protective oxide scales on the Ti6Al4V [33], resulting in poor wettability of Zn to Ti alloys and, therefore, failure to join Al and Ti alloys. Recently, using an electroplating process before the FSB process would produce a copper layer on the surface of graphite, which converted the graphite-copper lap joint to the similar joining of copper to copper [34]. This gives us an idea that pretreating the base metal will be a possible benefit for FSSB of Al and Ti.In the present paper, we utilized hot dip to aluminize T6Al4V alloys and developed a friction stir spot joining process, called friction stir spot w...

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Section: Parametric Studysupporting

confidence: 66%

Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

Zhou

Chen

et al. 2018

Metals

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“…To avoid this problem, Kuang BB et al [14] used Zn foil as filler metal to carry out friction stir lap welding (FSLW) of Al to pure Cu, as both Al and Cu could form alloys with Zn according to the phase diagram. The report about dissimilar FSW of Al to steel using Zn foil as filler metal is few.…”

Section: Accepted Manuscriptmentioning

confidence: 99%

“…To solve this dilemma, a wear resistant welding tool is necessary. In another way, the addition of the filler metal in this experiment may change this situation as the Zn foil could melt without inserting welding tool into it [14].…”

Section: Accepted Manuscriptmentioning

confidence: 99%

Dissimilar friction stir welding of 6061 Al to 316 stainless steel using Zn as a filler metal

Zheng

Feng

Shen

et al. 2016

Journal of Alloys and Compounds

Self Cite

110

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“…From the existing literature [19][20][21][22] the FSW process parameters such as tool rotational speed and transverse speed have significantly effect on the weld quality. Further, few studies concerning dissimilar metal welding, an additional process parameter namely inter-filler material of specific thickness was found to significantly affect the weld quality [17,23]. Preliminary experiments were performed using 3 mm thick plates of AA6063 aluminium alloy and ETP copper to fix the operational range of process parameters.…”

Section: Introductionmentioning

confidence: 99%

Research the Effect of Process Parameters on Friction Stir Welded AA6063-ETP Copper joint using Taguchi Technique

2019

IJRTE

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Aluminium and copper, or their combination finds application in heat sinks because of their excellent thermal conductivity. In the present study, Al–6063 and ETP copper were lap welded using friction stir welding wherein the aluminum alloy plate was placed on top of the copper plate. The optimum process parameters were found using Taguchi L9 orthogonal array. The process parameters namely tool rotational speed, tool traverse speed and thickness of zinc inter-filler material were considered. The optimal process parameters were ascertained with respect to the thermal conductivity of weld. The predicted optimum value of thermal conductivity was verified by conducting the confirmation run using the optimal parameters. Analysis of variance depicted that all the three process parameters were significant, wherein the tool rotational speed and the tool traverse speed were the most dominant factors contributing to thermal conductivity.

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The dissimilar friction stir lap welding of 1A99 Al to pure Cu using Zn as filler metal with “pinless” tool configuration

Cited by 80 publications

References 23 publications

Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

Friction Stir Spot Welding-Brazing of Al and Hot-Dip Aluminized Ti Alloy with Zn Interlayer

Dissimilar friction stir welding of 6061 Al to 316 stainless steel using Zn as a filler metal

Research the Effect of Process Parameters on Friction Stir Welded AA6063-ETP Copper joint using Taguchi Technique

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