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Friction Stir Welding of Al-Cu Bilayer Sheet by Tapered Threaded Pin: Microstructure, Material Flow, and Fracture Behavior

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Abstract

The fracture behavior and intermetallic formation are investigated after friction stir welding of Al-Cu bilayer sheets performed by tapered threaded pin. To do so, temperature, axial load, and torque measurements during welding, and also SEM and XRD analyses and tensile tests on the welds are carried out. These observations show that during welding from Cu side, higher axial load and temperature lead to formation of different kinds of Al-Cu intermetallics such as Al2Cu, AlCu, and Al4Cu9. Also, existence of Al(Cu)-Al2Cu eutectic structures, demonstrates liquation during welding. The presence of these intermetallics leads to highly brittle fracture and low strength of the joints. In samples welded from Al side, lower axial load and temperature are developed during welding and no intermetallic compound is observed which results in higher strength and ductility of the joints in comparison with those welded from Cu side.

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Acknowledgments

The authors wish to thank the research board of Sharif University of Technology and University of Coimbra for the financial support and the provision of the research facilities used in this work.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Sharif University of Technology, Azadi Avenue, Tehran, Iran

    R. Beygi, M. Kazeminezhad & A. H. Kokabi

  2. CEMUC, University of Coimbra, Rua Luís Reis Santos, 3030-788, Coimbra, Portugal

    R. Beygi & A. Loureiro

Authors
  1. R. Beygi
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  2. M. Kazeminezhad
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  3. A. H. Kokabi
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  4. A. Loureiro
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Correspondence to M. Kazeminezhad.

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Manuscript submitted July 11, 2014.

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Beygi, R., Kazeminezhad, M., Kokabi, A.H. et al. Friction Stir Welding of Al-Cu Bilayer Sheet by Tapered Threaded Pin: Microstructure, Material Flow, and Fracture Behavior. Metall Mater Trans A 46, 2544–2553 (2015). https://doi.org/10.1007/s11661-015-2859-7

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  • DOI: https://doi.org/10.1007/s11661-015-2859-7

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