Abstract
The fabrication of dissimilar joints for electrical applications raises challenges for conventional joining technologies. Within solid-state processes, friction stir welding (FSW) provides numerous advantages to realize different joint configurations. However, depending on the intermixing of the materials, defects like hooking and significant intermetallic compound formation around copper fragments are observed and lead to a decrease in joint properties. Therefore, stationary shoulder FSW was applied to produce 2 mm EN AW1050/CW024A lap joints with minimized intermixing at the interface. Compared to conventional FSW, the range of the friction-based heat input can be increased without risking excessive plastification under the tool shoulder. The influence of the pin length on the interfacial structure as well as the mechanical properties were investigated. A pin length of 2.2 mm and hence a plunging of approximately 0.2 mm into the lower copper sheet was found to obtain the highest failure load. A further increase caused the formation of hooking defects, which led to void formation at the interface and failure within the area of the thinned aluminium sheet. The results were also transferred to lap joints with a tin and silver interlayer of 10 µm and also showed good results in terms of bond strength and contact area.
Highlights
The substitution of copper by aluminium is widely pursued in order to save weight and material costs, especially in automotive battery applications
Lap joints between aluminium and copper were produced by stationary shoulder friction welding, Lap joints aluminium and copper were produced by stationary friction which allowsbetween the application of high rotational speeds due to less frictional heat input inshoulder the area close
Summary and Conclusions welding, which allows the application of high rotational speeds due to less frictional heat input to the tool shoulder
Summary
The substitution of copper by aluminium is widely pursued in order to save weight and material costs, especially in automotive battery applications. In terms of heat and wear minimization, most investigations are carried out with aluminium as the top sheet In this case, the penetration of the pin tip into the lower copper sheet determines the heat input at the interface, as the active stirring of copper leads to higher peak temperatures and the formation of the so-called hooking defect [30]. The penetration of the pin tip into the lower copper sheet determines the heat input at the interface, as the active stirring of copper leads to higher peak temperatures and the formation of the so-called hooking defect [30] This effect is caused by the material of the lower sheet being pulled into the top sheet by the pin. Takes place due to diffusion-based mechanisms instead of pronounced intermixing and interlocking
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