Abstract
The friction stir clinching (FSC) of C10100 and AA5456 alloys was investigated to improve the weld performance of the Al/Cu joint via the combined effect of protrusion-induced mechanical interlocking and metallurgical bonding. The microstructure, tensile, and fracture results of the friction stir clinched C10100/AA5456 joints were studied. The in-situ local temperature histories of the joints were recorded via the use of K-type thermocouples connected to a data logger. The peak temperatures of the joints at 900 rpm, 1120 rpm, and 1400 rpm are 332.4oC, 399.8oC, and 577.1oC respectively. The increase in the plunge depth (0.5 -1.5 mm) increases the amount of the extruded surface flash and the weld failure load of the joint while the increase in the tool rotational speed (900 - 1400 rpm) hampers the resultant failure load of the joint. The highest and the least failure loads of the joints are 2282 N and 1060 N respectively. The fracture modes of the joints include partially sheared protrusion, completely sheared protrusion, and undamaged protrusion/protrusion pullout. The completely sheared protrusion fracture mode produced the maximum failure load owing to the combined effect of protrusion-induced interlocking and metallurgical bonding. It is recommended to weld Al and Cu alloys at low tool rotational speed and high plunge depth for desirable metallurgical bond and Al/Cu interlock.
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