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Microstructural and mechanical analysis of achieving crack-free joints in high-speed friction stir spot welding of Cu–Al dissimilar material

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Abstract

Mixing materials is essential for good strength-to-weight ratio and cost-effectiveness in industrial applications which often requires the use of hybrid materials. The Al–Cu composite is vital in applications such as transformer foil conductors, electrical connections, capacitor foil windings, and heat exchanger tubes. However, joining aluminum (Al) and copper (Cu) components through spot welding presents challenges due to their distinct properties. This study employs Friction Stir Spot Welding (FSSWP) to connect Al and Cu, examining microstructural and mechanical aspects at tool speeds from 1000 to 1500 rpm. Scanning Electron Microscopy images aid in assessing weld quality. Tensile tests on single and double spot-welded specimens reveal that the optimal tool speed is 1500 rpm, with double welds displaying 6.8% higher tensile strength and a crack-free surface. This research suggests double spot-welded specimens as a substitute for pure copper, enhancing performance. Meanwhile, in the realm of finite element analysis using Deform 3D, understanding damage in friction stir welding emphasizes the importance of rotational speed. At 1000 RPM, it influences thermal issues, material flow, and tool wear. Achieving optimal FSW results necessitates precise control, post-weld treatments, and quality management, recognizing that damage levels vary based on material, thickness, and welding conditions.

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The data used to support the findings of this study are included in the article. Should further data or information be required, these are available from the corresponding author upon request.

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Acknowledgements

The authors appreciate the technical assistance to complete this experimental work from Department of Mechanical Engineering, Saveetha School of Engineering, SIMATS, Chennai, and Saranathan College of Engineering, Trichy, Tamil Nadu, India. The authors thank for the technical assistance to complete this experimental work.

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Authors declared that no funding was received for this Research and Publication.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Sri Jayaram Institute of Engineering and Technology, Gummidipoondi, Chennai, India

    K. Raja & N. Ramanan

  2. Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences (SIMATS), Thandalam, Chennai, India

    A. Bovas Herbert Bejaxhin

  3. Department of Mechanical Engineering, Sree Sakthi Engineering College, Coimbatore, India

    G. Jayaprakash

  4. Department of Mechanical Engineering, Dr.N.G.P Institute of Technology, Coimbatore, India

    P. Gopi Krishnan

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  1. K. Raja
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  2. A. Bovas Herbert Bejaxhin
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  4. P. Gopi Krishnan
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  5. N. Ramanan
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Contributions

KR—Research methodology and Novelty of the project. ABHB—Experimental and prediction outcomes. GJ—Design and Analysis, Consolidation of data and drafting. PG—Results and discussion, validation. NR—Drafting and formatting.

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Correspondence to A. Bovas Herbert Bejaxhin.

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Raja, K., Bejaxhin, A.B.H., Jayaprakash, G. et al. Microstructural and mechanical analysis of achieving crack-free joints in high-speed friction stir spot welding of Cu–Al dissimilar material. Int J Interact Des Manuf (2024). https://doi.org/10.1007/s12008-024-01747-9

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