Abstract
Producing joints of aluminum and copper by means of fusion welding is a challenging task. However, the results of various studies have proven the potential of friction stir welding (FSW) for manufacturing aluminum-copper joints. Despite the proven feasibility, there is currently no series application in automotive industry to produce aluminum-copper joints for electrical contacts by means of FSW. To make FSW as efficient as possible for large-scale production, maximized welding speed is desired. Taking this into account, this paper presents results of a parametric investigation, the objective of which was to increase the welding speed for FSW of aluminum and copper in comparison to welding speeds that are considered to be state of the art. Taguchi method was used to design an experimental plan and target figures of the investigations were the resultant tensile strengths and electrical resistances. Dependencies between input parameters and target figures were determined systematically. The optimal welding parameters, at which joints failed in the weaker aluminum material, included a welding speed of 700 mm/min. Consequently, it could be shown that joints with a performance similar to those of the base materials can be obtained using significantly higher welding speeds than reported in the relevant literature.
Highlights
Excellent electrical and thermal conductivity combined with high ductility, creep resistance and corrosion resistance are the reasons for copper materials being considered to be state of the art in current-carrying components for automotive applications
Dissimilar aluminum-copper joints represent a solution with great potential for weight and cost-optimized conductors [1,2]
This study addresses a research questions that is of particular relevance to the use of Friction stir welding (FSW) for the production of aluminum-copper joints in the automotive industry
Summary
Excellent electrical and thermal conductivity combined with high ductility, creep resistance and corrosion resistance are the reasons for copper materials being considered to be state of the art in current-carrying components for automotive applications. Using copper is disadvantageous regarding the high procurement costs and the high material density. Taking this into account, dissimilar aluminum-copper joints represent a solution with great potential for weight and cost-optimized conductors [1,2]. Joining aluminum and copper is a challenging task by means of conventional fusion welding. Different melting temperatures of the base materials, the high thermal conductivities, and the low mutual solubility, which leads to the formation of brittle intermetallic phases, make it difficult to achieve sound welds [4].
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