Welding parameters analysis and microstructural evolution of dissimilar joints in Al/Bronze processed by friction stir welding and their effect on engineering tensile behavior

Zoeram, A. Shojaei; Anijdan, S.H. Mousavi; Jafarian, H.R.; Bhattacharjee, Tilak

doi:10.1016/j.msea.2017.01.071

Cited by 36 publications

(17 citation statements)

References 20 publications

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“…FSW can be commonly used to join nonferrous light and plastic metals such as Al, Mg and Ti alloys with other dissimilar metal alloys that are hard to weld by conventional fusion welding [2,5,14,15,16,17,18]. Recently, FSW has also been recognized as an effective technique to overcome the welding problems of Al–Cu dissimilar joints [19,20,21,22,23,24,25,26,27]. Some studies indicated that not only the welding quality, but also mechanical properties of Al–Cu dissimilar joints are significantly influenced by controlling the FSW parameters [21,22,23,24,25] and microstructural features, especially for the intermetallic compounds (IMCs) layer formed at the bonding interface within the welding zone of Al–Cu dissimilar joints [26,27,28,29,30,31].…”

Section: Introductionmentioning

confidence: 99%

“…Recently, FSW has also been recognized as an effective technique to overcome the welding problems of Al–Cu dissimilar joints [19,20,21,22,23,24,25,26,27]. Some studies indicated that not only the welding quality, but also mechanical properties of Al–Cu dissimilar joints are significantly influenced by controlling the FSW parameters [21,22,23,24,25] and microstructural features, especially for the intermetallic compounds (IMCs) layer formed at the bonding interface within the welding zone of Al–Cu dissimilar joints [26,27,28,29,30,31]. The brittleness of the IMCs layer usually results in easier cracks propagation and failures at the joint interface [32,33].…”

Section: Introductionmentioning

confidence: 99%

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Weibull Statistical Analysis of Strength Fluctuation for Failure Prediction and Structural Durability of Friction Stir Welded Al–Cu Dissimilar Joints Correlated to Metallurgical Bonded Characteristics

Yang

Jiang

2019

Materials

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In this paper, dissimilar Al–Cu joints of AA1050H/C1100-Cu, AA6061-T6/C1100-Cu, and AA1050H/C2600-brass are successfully welded by a friction stir welding (FSW) process. The aim of the present study is not only to examine the tensile strength, but also to investigate the reliability, durability, and failure behaviors of joints as correlated with the metallurgical bonded microstructures of varied Al–Cu joints. Experimental evidence confirms that good welding quality for an FSW Al–Cu dissimilar joint is obtained when pure Cu and brass plates are positioned at the advancing side. Cross-sectional microstructures reveal that the AA6061-T6/C1100-Cu joint exhibits an extensive metallurgical bonded region with significant onion rings in the welding zone, whereas the AA1050H/C2600-brass joint generally displays a clear mechanical kissing bonded boundary at the joint interface. Al2Cu, Al4Cu9, and γ-Cu5Zn8 are major intermetallic compounds (IMCs) that are formed within the metallurgical bonded welding zone. The Weibull model provides a statistical method for assessing the failure mechanism of FSW Al–Cu joints. Better welding reliability and tensile properties with ductile dimpled ruptures are obtained for the Al–Cu joints with a typical metallurgical bonded zone. However, a mechanical kissing bonded interface and thick interfacial IMCs result in the deterioration of tensile strength with a brittle fracture and a rapid increase in the failure probability of Al–Cu joints.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Weibull Statistical Analysis of Strength Fluctuation for Failure Prediction and Structural Durability of Friction Stir Welded Al–Cu Dissimilar Joints Correlated to Metallurgical Bonded Characteristics

Yang

Jiang

2019

Materials

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“…The rotating tool pin moves the plasticized material from the front to the back of the weld line which results in joining between the butted plates. FSW is widely used for light alloys (Al [2,4,5], Mg [6] and Ti [7]), Cu-based alloys [8], steels [9] and dissimilar metals (Al/Mg [10][11][12], Al/Steel [13][14][15], Al/Cu [16][17][18][19], Al/Bronze [20] and duplex stainless steel (DSS)/low alloy steel [21]). So far, there are no experimental reports on FSW of DSS and Cu alloys.…”

Section: Introductionmentioning

confidence: 99%

“…The identified IMC layer consisted of two Al 2 Cu and Al 4 Cu 9 sub-layers. Zoeram et al [20] have reported that the heat of friction leads to formation of an intermetallic layer at the joint interface of Al and bronze. The thickness of this IMC layer had an important role on the tensile strength of the joints.…”

Section: Introductionmentioning

confidence: 99%

Effect of friction stir welding parameters on microstructure and mechanical properties of DSS–Cu joints

Shokri

Sadeghi

2017

Materials Science and Engineering: A

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Dissimilar joining of copper to duplex stainless steel (DSS) is challenging at high temperatures of fusion welding owing to the large difference in physical properties of the base metals. To reduce negative effects of welding at high temperatures, solid state welding at lower temperatures has been proposed. To study different effects of welding parameters (rotation speed, travel speed and tool offset) on weld zone microstructure and mechanical properties butt joints of a copper alloy and duplex stainless steel (DSS) were produced by friction stir welding (FSW). It has been found that heat input generated by the interaction of different welding conditions has a significant effect on the formation of a brittle intermetallic at the interface and eventually the final mechanical properties. At low heat inputs, mixing of the two sides is insufficient and metallurgical bonding is weak; while at high heat inputs, the thickness of the formed intermetallic is too thick which causes stress concentration at the interface and premature failure. An optimum welding condition was found (rotation speed of 1200 rpm, travel speed of 30 mm/min and tool offset of 0.5 mm) which almost reached the mechanical properties of the Cu-alloy monolayer.

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“…Joining AA3003 is faced with manufacturing complications when fabrication of multi-component industrial parts is involved [2]. Many different approaches have been recently developed or utilized in joining similar or dissimilar metals and alloys to each other [3][4][5]. The utilized welding process would not necessarily result in reduced mechanical properties, as for example, it has been observed in many different alloys, that application of friction stir processing has yielded significantly improved properties [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

Effect of process conditions on the evolution of microstructure and mechanical properties of AA3003 vacuum furnace brazing joints

Eivani

Ahmadian²,

Vafaeenezhad

2020

Mater. Res. Express

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In this study, vacuum furnace brazing was used for joining AA3003 alloy with different thicknesses of 0.6 and 3 mm using BALSI-4 filler metal. Firstly, the samples were degreased using water and soap and then cleaned with acetone. The set-up was assembled and pre-heated for two-steps at 235 and 339°C and subsequently, moved to furnace. Vacuum brazing was conducted at temperature range of 590 to 630°C for different holding times of 5 and 10 min followed by furnace cooling. After primary visual checking, three samples for each thickness were selected for evaluation of microstructure and mechanical properties. Results indicated that furnace temperature and holding time significantly influenced microstructural evolution and mechanical properties. This effect was attributed to the distribution of Si and its relevant eutectic and pro-eutectic phases. It was deduced that the amount and distribution of such phases together with joint assembling design controlled the mechanical and fracture behavior. Furthermore, it was found that the quantitative amounts of pro-eutectic Si and Al-Si eutectic phases significantly increased the hardness of the joint. Therefore, the joint brazed at 610°C and dwelling time of 10 min was identified to offer the optimal mechanical properties.

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Welding parameters analysis and microstructural evolution of dissimilar joints in Al/Bronze processed by friction stir welding and their effect on engineering tensile behavior

Cited by 36 publications

References 20 publications

Weibull Statistical Analysis of Strength Fluctuation for Failure Prediction and Structural Durability of Friction Stir Welded Al–Cu Dissimilar Joints Correlated to Metallurgical Bonded Characteristics

Weibull Statistical Analysis of Strength Fluctuation for Failure Prediction and Structural Durability of Friction Stir Welded Al–Cu Dissimilar Joints Correlated to Metallurgical Bonded Characteristics

Effect of friction stir welding parameters on microstructure and mechanical properties of DSS–Cu joints

Effect of process conditions on the evolution of microstructure and mechanical properties of AA3003 vacuum furnace brazing joints

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