Abstract
Dissimilar welding of aluminium (Al) and copper (Cu) has many applications in the electric power, electronic and piping industries. The weldments in these applications are highly valued for their corrosion resistance, heat and electricity conducting properties. The Al-Cu joints are lighter, cheaper and have conductivity equal to that of copper alloys. Much research has investigated dissimilar welding of Al-Cu by solid-state welding and fusion welding processes with the aim of optimising the properties and strength of such dissimilar joints. The main aim of the study is to critically review the factors influencing the properties of the Al-Cu joint. The study mainly discusses about the effects of intermetallic compounds (IMC) on the properties of Al-Cu joint and their effect while in service. The effects of joining aluminium alloy 1060 with pure copper by laser welding, friction stir welding and brazing have been reviewed and compared. The review shows that the various intermetallic compound formations in the joint have both beneficial and detrimental effects. The characteristics of these intermetallic compounds vary according to the location of the phase formed. Comparison of processes and parameters for welding of Al 1060 with pure Cu shows that the formation of the intermetallic compounds and their effects on the weld properties are mainly influenced by the welding speed, heat input, the thermal properties of the base metals and the filler metal as well as the dilution between the base metal and filler metal.
Highlights
Many industries such as the marine, aerospace, petrochemical and automobile industries have recognised the potential of dissimilar welding of metals to provide safe structures that can operate in fluctuating service conditions while at the same time offering manufacturing cost savings
The mechanical properties of Al-Cu joints can be reduced by brittle intermetallic compound phases formed during welding
Al-Cu joints are difficult to manufacture by fusion welding processes due to the significant difference in the chemical composition and physical properties of the base metals
Summary
Many industries such as the marine, aerospace, petrochemical and automobile industries have recognised the potential of dissimilar welding of metals to provide safe structures that can operate in fluctuating service conditions while at the same time offering manufacturing cost savings. The welding parameters influencing the dilution reduce the formation of brittle intermetallic compounds in the weld metal From these studies, it is clear that the inappropriate selection of filler metal corresponding to base metals in the brazing process and improper welding tool position in the friction stir welding resulted in improper dilution between the base metals and filler metal. It is clear that the inappropriate selection of filler metal corresponding to base metals in the brazing process and improper welding tool position in the friction stir welding resulted in improper dilution between the base metals and filler metal This in turn produced brittle intermetallic compounds, which results in degradation of properties and defect formation. The degradation in weld properties can be avoided by considering the difference in melting temperature during the joint design stage and by the use of suitable filler metal and welding parameters
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