Abstract
Friction Stir Welding (FSW) can be performed to join dissimilar metal combinations like aluminium and copper, which is of high interest in modern production of electrical applications. The amount of intermetallic phases in the weld seam is significantly reduced compared to traditional fusion welding technologies. Because the solidus temperature is typically not reached during FSW, the growth of intermetallic phases is impeded and the intermetallic layer thicknesses typically remains on the scale of a few hundred nanometres. These layers provide a substance-to-substance bond, which is the main joining mechanism. Latest research confirms that the layer formation is most likely driven by the heat input during processing. Hence, the welding temperature is the key to achieve high quality joints. In this study, aluminium and copper sheets were welded in lap joint configuration using temperature-controlled FSW. An advanced in-tool measurement set-up was used to determine precise temperature data. Scanning electron microscopy (SEM) was used to analyse metallurgical aspects (e.g. structure and composition of the intermetallic phases) of the joints. The results show a correlation between the welding temperature and the thickness of the intermetallic layer and its structure. The temperature control significantly improved the correlation compared to previous studies. This leads to an enhanced understanding of the dominating joining mechanisms.
Highlights
Introduction and state of the artThe recent changes in automotive design and construction require welding technologies, which are capable of joining dissimilar metals
Because the solidus temperature is typically not reached during Friction Stir Welding (FSW), the growth of intermetallic phases is impeded and the intermetallic layer thicknesses typically remains on the scale of a few hundred nanometres
Aluminium and copper sheets were welded in lap joint configuration using temperature-controlled FSW
Summary
- Formation of a diffusion-based intermetallic interface layer in friction stir welded dissimilar Al-Cu lap joints R Marstatt, M Krutzlinger, J Luderschmid et al. - Influence of the welding temperature and the welding speed on the mechanical properties of friction stir welds in EN AW2219-T87 A Bachmann, M Krutzlinger and M F Zaeh. - Mechanical behaviour of Al 2024 alloy welded by friction stir welding M Mili, T Vuherer, I Radisavljevi et al. This content was downloaded from IP address 137.250.100.44 on 17/02/2020 at 06:18
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