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Evaluation of microstructure and mechanical properties of aluminum to copper friction stir butt welds

Sarrafi, R ; Sharif University of Technology | 2011

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  1. Type of Document: Article
  2. DOI: 10.1002/9781118062302.ch31
  3. Publisher: 2011
  4. Abstract:
  5. A high-quality butt joint of aluminum to copper (Al/Cu) can rarely be achieved by conventional fusion and solid-state welding processes. In this research, the appropriateness of friction stir welding (FSW) for making high-quality Al/Cu welds was studied. A sound Al/Cu butt joint was achieved with relatively high strength in uni-axial tensile tests. Mechanical properties and microstructure of the sound friction stir welds were examined. The ultimate tensile strength of the joints reached about 75 percent of the aluminum base metal, with the fracture occurring at aluminum side. The metallurgical study of the welds before and after their failure in tensile tests showed that the heat affected zone of aluminum controls the strength of the joints in tensile loading. Microstructural features of the stir zone (SZ) included a relatively small volume fraction of intermetallic compounds and their discreteness. The presence of these phases has been demonstrated not to have a considerable harmful effect on the weld tensile properties. The formation of the mentioned microstructure in the SZ is probably due to limited interdiffusion of aluminum and copper atoms, i.e., insignificant alloying, as well as intense mechanical stirring in the welding process
  6. Keywords:
  7. Base metals ; Butt joints ; Butt welds ; Copper atoms ; Dissimilar welding ; Friction stir ; Friction stir welds ; Harmful effects ; High quality ; High strength ; Mechanical stirring ; Microstructural features ; Microstructure and mechanical properties ; Properties and microstructures ; Solid-state welding process ; Stir zones ; Tensile loading ; Tensile tests ; Ultimate tensile strength ; Weld microstructure ; Welding process ; Aluminum ; Butt welding ; Copper ; Electric welding ; Friction ; Gas welding ; Heat affected zone ; Intermetallics ; Mechanical properties ; Microstructural evolution ; Stainless steel ; Tensile strength ; Tensile testing ; Tribology ; Friction stir welding
  8. Source: TMS Annual Meeting, 27 February 2011 through 3 March 2011 ; March , 2011 , Pages 253-264 ; 9781118002018 (ISBN)
  9. URL: http://onlinelibrary.wiley.com/doi/10.1002/9781118062302.ch31/summary