Abstract
In this investigation, dissimilar material AA6061-T6 and Cu B370 were joined by friction stir welding (FSW). This paper presents a feasibility study of FSW to join Al-alloy and Cu-alloy. The experiment was conducted using general full factorial design by varying the tool rotation speed, weld speed, and probe offset, and by keeping the plunge depth constant. In this research work, a statistical model was established to build a connection between the process variables and outcomes—yield strength (YS), ultimate tensile strength (UTS) and % elongation (% E). Statistical tools such as analysis of variance and scatter diagrams were employed to evaluate the suitability of the models. In addition, the impacts of the process variables on the tensile properties were investigated. From the experimental results, it can be concluded that (i) an excellent weld joint could be obtained by keeping the softer Al plate at the retreating side with a probe offset of 2.0 mm towards the softer material, and (ii) maximum tensile properties were obtained at a higher tool-rotation speed, weld speed, and with a probe offset of 2.0 mm. Further, the fractured tensile specimens were investigated using a scanning electron microscope (SEM). From the analyses, it was noted that, during the tensile test, the weld joint failed with a brittle–ductile mixed fracture mode.
Highlights
In a conventional welding process, the joining of dissimilar materials, such as different grades of aluminum (Al) and copper (Cu), is considered to be a major challenge
The generated temperature is below the melting point of the base materials, which helps the base materials to attain an elastic phase and be fused to each other [2]
The formation of a joint without using additional filler materials, alloying elements, and arc, reduces the chances of welding defects that occur in fusion welding
Summary
In a conventional welding process, the joining of dissimilar materials, such as different grades of aluminum (Al) and copper (Cu), is considered to be a major challenge This is due to the variations in the mechanical, chemical, and thermal properties of Al and Cu. FSW is one of the most promising solid-state joining processes, which can join the same or different base materials [1]. Sorger et al developed an innovative overlap joint concept for single pass and multi pass configurations of the joining of Al with steel using the FSW process They concluded that with a two-pass weld, the mechanical properties of the joints were improved. Lukacs et al investigated the fatigue properties of dissimilar FSW joints of aluminum alloys and found a good correspondence in fatigue properties in a comparative analysis of base materials and welded joints [25,26].
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