Dissimilar Joining of Pure Copper to Aluminum Alloy via Friction Stir Welding

doi:10.1007/s40195-018-0741-5

Abstract

Abstract:

In this study, the dissimilar friction stir welding (FSW) butt joints between aluminum alloy 5754-H114 and commercially pure copper were investigated. The thickness of welded plates was 4 mm and the aluminum plate was placed on the advancing side. In order to obtain a suitable flow and a better material mixing, a 1-mm offset was considered for the aluminum plate, toward the butt centerline. For investigating the microstructure and mechanical properties of FSWed joints, optical microscopy and mechanical tests (i.e., uniaxial tensile test and microhardness) were used, respectively. Furthermore, the analysis of intermetallic compounds and fracture surface was examined by scanning electron microscopy and X-ray diffraction. The effect of heat generation on the mechanical properties and microstructure of the FSWed joints was investigated. The results showed that there is an optimum amount of heat input. The intermetallic compounds formed in FSWed joints were Al4Cu9 and Al2Cu. The best results were found in joints with 1000 rpm rotational speed and 100 mm/min travel speed. The tensile strength was found as 219 MPa, which reached 84% of the aluminum base strength. Moreover, maximum value of the microhardness of the stir zone (SZ) was attained as about 120 HV, which was greatly depended on the grain size, intermetallic compounds and copper pieces in SZ.

Key words: Friction stir welding, 5754-H114 aluminum alloy, Pure copper, Heat generation, Microstructure, Intermetallic compounds

Farhad Bakhtiari Argesi, Ali Shamsipur, Seyyed Ehsan Mirsalehi. Dissimilar Joining of Pure Copper to Aluminum Alloy via Friction Stir Welding[J]. Acta Metallurgica Sinica (English Letters), 2018, 31(11): 1183-1196.

Figures/Tables 17

Table 1 Compositions of AA5754-H114 and C10100 (wt%)

Material	Si	Fe	Cu	Mn	Mg	Cr	Zn	Al
AA 5754-H114	0.16	0.14	0.05	0.33	2.9	0.12	0.09	bal
Material	Pb	Fe	P	Ag	As	Sb	Zn	Cu
C10100	0.0005	0.001	0.0003	0.0025	0.0005	0.0004	0.0001	99.99

Fig. 1 Thread tapered tool and its dimensions

Fig. 2 Schematic of friction stir welding between AA5754-H114 and pure copper

Table 2 Welding parameters and the FSWed specimens

Specimen number	Specimen code	Rotation speed, ω (rpm)	Travel speed, v (mm min^-1)	Heat generation, ω²/v (rpm²/(mm min^-1))
1	800-50	800	50	12,800
2	800-100	800	100	6400
3	900-50	900	50	16,200
4	1000-50	1000	50	20,000
5	1000-100	1000	100	10,000

Fig. 3 Appearance of FSWed 800-100 specimen

Fig. 4 Macrostructures of FSWed specimens: a 800-100, b 1000-100, c 800-50, d 900-50, e 1000-50

Fig. 5 Microstructures of a AA5754-H114, b commercial pure copper

Fig. 6 Various regions for 1000-100 specimen: a HAZ-Al, b TMAZ-Al, c SZ-Al, d macrostructure of joint, e SZ-Cu, f TMAZ-Cu, g HAZ-Cu

Fig. 7 Microstructures of SZ and HAZ of FSWed specimens

Fig. 8 Grain size of FSWed specimens

Fig. 9 Binary phase diagram Al-Cu [29]

Fig. 10 SEM image of 1000-100 FSWed specimens; a SZ image at secondary electron mode, b SZ image at backscatter mode, c magnification of A area, d EDX mapping of A area, e linear analysis at A area

Fig. 11 Microhardness distributions of FSWed specimens

Fig. 12 Tensile properties of FSWed specimens

Fig. 13 Influence of heat generation on ultimate tensile strength

Fig. 14 Fracture surfaces of FSWed specimens; a 800-100, b 1000-100, c 800-50, d 900-50, e 1000-50

Fig. 15 XRD patterns of FSWed specimens; a 1000-100, b 1000-50

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