Skip to main content
SpringerLink
Log in

Tensile Strength and Hardness Correlations with Microscopy in Friction welded Aluminium to Copper

  • Article of professional interest
  • Published:
Journal of The Institution of Engineers (India): Series C Aims and scope Submit manuscript

Abstract

Aluminium and copper are good conductors of heat and electricity, copper being the better conductor, is a costly metal indeed. On the other hand, aluminium is cheap, easily available and also has a lower density than copper. Hence, worldwide efforts are being made to partially replace copper wire. Solid state welding should be used to join aluminium to copper. This is because the use of fusion welding results in brittle phases formed in the weld interface. One of the solid state welding techniques used for joining aluminium to copper is friction welding. In this paper, an attempt has been made to join aluminium to copper by friction welding by varying the friction welding parameters, namely friction pressure, upset pressure, burn-off length and speed of rotation of the workpiece. Nine different friction welding parameter combinations were used during welding in accordance with ASTM standards and results have been reported. Tensile strength and hardness tests were carried out for each parameter combination. Optimum friction welding parameter combination was identified with respect to tensile strength. Scanning Electron Microscopy and Electron dispersive spectroanalysis were obtained to identify modes of fracture and presence of intermetallic phases for each friction welding combination with the aim to narrow down friction welding parameters that give good properties on the whole.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3
Fig. 4

Similar content being viewed by others

References

  1. C.H. Kim, Y.N. Ahn, J.H. Kim, CO2 laser-micro plasma arc hybrid welding for galvanized steel sheets. Trans. Non-Ferr. Soc. China 21, 47–53 (2011)

    Article  MathSciNet  Google Scholar 

  2. M. Abbasi, A.K. Taheri, M.T. Salehi, Growth rate of intermetallic compounds in Al/Cu bimetal produced by cold roll welding process. J. Alloys Compd. 319, 233–241 (2001)

    Article  Google Scholar 

  3. K. Thomas, M. Petri, Roll welding. ASM weld. Hand Book 6, 312–314 (1994)

    Google Scholar 

  4. M. Gao, X. Zeng, H. Qianwu, J. Yan, Laser-TIG hybrid welding of ultra-fine grained steel. J. Mater. Process. Technol. 209, 785–791 (2009)

    Article  Google Scholar 

  5. G. Esser, I. Mys, L. Schmidt, Micro-welding of copper and aluminium. Proc Fifth Int. Symp. Laser Precis. Microfab. 5662, 337–342 (2004)

    Google Scholar 

  6. T. Ueoka, J. Tsujino, Welding characteristics of aluminium and copper plate specimens welded by a 19 kHz Ultrasonic seam welding system, Jpn. J. Appl. Phys. 4l, 3237–3242 (2002)

    Article  Google Scholar 

  7. D. Hidefumi, N. Masaaki, Impact welding of A1 onto Cu by the gas gun method. Plans. JWRI 27(2), 31–36 (1998)

    Google Scholar 

  8. J. Ouyang, E. Yarrapareddy, R. Kovacenic, Microstructural evolution in the friction stir welded 6061 Al–alloy to copper. J. Mater. Process. Technol. 172, 110–122 (2006)

    Article  Google Scholar 

  9. W.F. Haessly, Flash welding aluminium to copper tubing. Weld. J. 12, 1162–1170 (1954)

    Google Scholar 

  10. H. Ochi, K. Ogawa, Y. Yamamoto, K. Fuji, Y. Suga, Influence of welding conditions on strength of Aluminium alloy to Copper, in Proceedings of the International Offshore and Polar Engineering Conference (1991) ISBN 1-880653-39-7 (Set); ISBN 1-880653-43-5 (Vol. IV); ISSN 1098-6189 (Set)

  11. I. Galvão, J.C. Oliveira, A. Loureiro, D.M. Rodrigues, Formation and distribution of brittle structures in friction stir welding of aluminium and copper. Intermetallics 22, 122–128 (2012)

    Article  Google Scholar 

  12. M. Sahin, Joining of aluminium and copper materials with friction welding. Int. J. Adv. Manuf. Technol. 49(5-8), 527–584 (2009)

    Article  Google Scholar 

Download references

Acknowledgments

The authors are very grateful to the management of St. Joseph’s College of Engineering and financial support from SSN College of Engineering. They are also thankful to MetMech laboratories, Guindy for assistance in Mechanical testing.

Author information

Authors and Affiliations

  1. St. Joseph’s College of Engineering, Chennai, 600119, Tamil Nadu, India.

    Rengarajan Satish & Vaddi Seshagiri Rao

  2. Siva Subramaniam Nadar College of Engineering, Chennai, 603110, Tamil Nadu, India.

    Dattaguru Ananthapadmanaban

  3. Larsen and Toubro Pvt. Ltd., Chennai, 600041, Tamil Nadu, India.

    Balappa Ravi

Authors
  1. Rengarajan Satish
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Vaddi Seshagiri Rao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dattaguru Ananthapadmanaban
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Balappa Ravi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Dattaguru Ananthapadmanaban.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Satish, R., Seshagiri Rao, V., Ananthapadmanaban, D. et al. Tensile Strength and Hardness Correlations with Microscopy in Friction welded Aluminium to Copper. J. Inst. Eng. India Ser. C 97, 121–126 (2016). https://doi.org/10.1007/s40032-015-0187-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40032-015-0187-8

Keywords

Search

Navigation