Skip to main content
SpringerLink
Log in

Improved performance of a heterogeneous weld joint of copper-steel AISI 1045 obtained by rotary friction using a metal powder insert

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Rotary friction welding is a means of assembly used in different fields even to perform heterogeneous welds. These latter obtained by conventional techniques in the liquid phase present several difficulties. The fragility of the bead is not only due to the induced metallurgical transformations, but also to the morphology of the interface serving as a physical junction. Then, the hard and brittle intermetallic compounds formed in a non-equilibrium matrix frequently affect the quality and performance of the solder joint. However, the metallurgical bonds obtained by interdiffusion of chemical elements on either side of the interface, in the solid state, often exhibit satisfactory solutions. One of our objectives in the present work consists in attenuating the extent of these undesirable intermetallic compounds, by diluting them in a heterogeneous solution, composed of the two materials to be assembled. It is worth noting that a concentration of stresses may be due not only to a geometric or structural defect, but also to a sudden change of material properties. To avoid such a situation, we propose the technique of inserting a mixture of metallic powders, between the two materials to be joined by rotary friction. This technique consists of going from one material to another in a continuous and progressive way by crossing the powder mixture between them. This allows improvement of certain mechanical and metallurgical characteristics of the solder joint. This technique is implemented and a microstructural and mechanical characterization is carried out on the obtained welded joints between commercial pure copper and carbon steel.

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.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29

Similar content being viewed by others

Data availability

The authors confirm that the data supporting the findings of this study are available within the article. The raw data that support the findings of this study are available upon a reasonable request.

Code availability

Finite difference method with the use of the Fortran power station compiler.

Abbreviations

Cp(i,j):

Specific heat to the node (i, j)

d:

Diameter of the parts to be welded

e:

Thickness of the metal powder

F:

Frictional force

f:

Dynamic coefficient of friction

h:

Coefficient of convection

k(i,j):

Thermal conductivity to the node (i,j)

L:

Total length of the two pieces

L1 :

Length of the stationary part

L2 :

Length of the rotating part

N:

Rotation speed

n:

Number of rows of particles

P:

Friction pressure

Pforg :

Forging pressure

r:

Radial position

rI(i):

Positions of interfaces along r

S:

Source term

T:

Temperature

t:

Time

z:

Axial position

ε:

Thickness of a range of particles

Δt:

Time step

ρ(i,j):

Density at the node (i, j)

i:

Increment in radial direction

j:

Increment in axial direction

References

  1. Shiri SG, Nazarzadeh M, Sharifitabar M, Afarani MS (2012) Gas tungsten arc welding of CP-coper to 304 stainless steel using different filler materials. Trans Nonferrous Met Soc China 22:2937–2942. https://doi.org/10.1016/S1003-6326(11)61553-7

    Article  Google Scholar 

  2. Bell RA, Lippold JC, Adolphson DR (1984) An Evaluation of copper-stainless steel inertia friction welds , initial surface condition has a significant effect on weld quality. Weld Res Suppl 325-s–332-s

  3. Kimura M, Kusaka M, Kaizu K, Fuji A (2009) Effect of friction welding condition on joining phenomana and tensile strength of friction welded joint between pure copper and low carbon steel. J Solid Mech Mater Eng 3(2):187–198. https://doi.org/10.1299/jmmp.3.187

    Article  Google Scholar 

  4. Dawson RJC (1983) Welding of copper and copper-base alloys. Weld Res Council Bulletins, WRC Bulletin 287:1–17

    Google Scholar 

  5. Dyja H (1996) Joints of steel-brass one-side welded by explosive method. Acta Phys Pol, A 89(3):411–415. https://doi.org/10.12693/APhysPolA.89.411

    Article  Google Scholar 

  6. Şahin M (2010) Friction welding of différent materials. Unitech, International scientific conference, Gabrovo II-131–134

  7. Meshram SD, Mohandas T, Madhusudhan G, Reddy G (2007) Friction welding of dissimilar pure matals. J Mater Process Technol 184(1–3):330–337. https://doi.org/10.1016/j.jmatprotec.2006.11.123

    Article  Google Scholar 

  8. Kurt A, Uygur I, Paylasan U (2011) Effect of friction welding parameters on mechanical and microstructural properties of dissimilar AISI 1010-ASTM B22 Joints. Weld Res 90(5):102–106

    Google Scholar 

  9. Sahin AZ, Yibas BS, Ahmed M, Nickel J (1998) Analysis of the friction welding process in relation to the welding of copper and steel bars. J Mater Process Technol 82(1–3):127–136. https://doi.org/10.1016/S0924-0136(98)00032-6

    Article  Google Scholar 

  10. Sahin M (2009) Joining of stainless steel and copper materials with friction welding. Ind Lubr Tribol 61(6):319–324. https://doi.org/10.1108/00368790910988435

    Article  Google Scholar 

  11. Fernando C, Ananthapadmanaban D, Sathish R (2011) Experimental observations on friction weldability of copper with steel. International Journal of Applied Engineering Research ISSN 0973–4562 6(20):2349–2355. http://www.ripublication.com/ijaer.htm

  12. Natsume S (1999) Different material welding. Weld Technol 47(6):98–104

    Google Scholar 

  13. Magnabosco I, Ferro P, Bonollo F, Arnberg L (2006) An investigation of fusion zone microstructures in electron beam welding of copper–stainless steel. Mater Sci Eng A 424:163–173. https://doi.org/10.1016/j.msea.2006.03.096

    Article  Google Scholar 

  14. Mai TA, Spowage AC (2004) Characterisation of dissimilar joints in laser welding of steel–Kovar, copper–steel and copper–aluminium. Mater Sci Eng A 374:224–233. https://doi.org/10.1016/j.msea.2004.02.025

    Article  Google Scholar 

  15. Yao C, Xu B, Zhang X, Huang J, Fu J, Wu Y (2009) Interface microstructure and mechanical properties of laser welding copper–steel dissimilar joint. Opt Lasers Eng 47:807–814. https://doi.org/10.1016/j.optlaseng.2009.02.004

    Article  Google Scholar 

  16. Durgutlu A, Gulence B, Findik F (2005) Examination of copper / stainless steel joints formed by explosive welding. Mater Des 26:497–507. https://doi.org/10.1016/j.matdes.2004.07.021

    Article  Google Scholar 

  17. Yilbas BS, Sahin AZ, Kahraman N, Al-Garni AZ (1995) Friction welding of St-Al and Al-Cu materials. J Mater Process Technol 49(3–4):431–443. https://doi.org/10.1016/0924-0136(94)01349-6

    Article  Google Scholar 

  18. Ochi H, Ogawa K, Yamamoto Y, Kawai G, Sawai T (2004) The formation of intermetallic compounds in aluminium alloy to copper friction-welded joints and their effect on joint efficiency. Weld Int 18(7):516–523. https://doi.org/10.1533/wint.2004.3282

    Article  Google Scholar 

  19. Ay I, Çelik S, Çelik I (1999) Comparison of properties of friction and diffusion welded joints made between the pure aluminium and copper bars. BAÜ Fen Bilimleri Enstitüsü Dergisi 1(2):88–102

    Google Scholar 

  20. Imani Y, Besharati Givi MK, Guillot M (2012) Improving friction stir welding between copper and 304L stainless steel. Adv Mater Res 409:263–268. https://doi.org/10.4028/www.scientific.net/AMR.409.263

    Article  Google Scholar 

  21. Abdelsalam AB, Ridwan MM (2012) experimental investigations on friction welding of dissimilar metals. Sudan Eng Soc J 58; No.1

  22. Lee WB, Jung SB (2003) Effect of microstructural variation on the Cu / CK45 carbon steel friction weld joint. Zeitschrift fur Metallkunde, Int J Mater Res Adv Techn 94(12):1300–1306

    Google Scholar 

  23. Wang Y, Luo J, Wang X, Xu X (2013) Interfacial characterization of T3 copper/35CrMnSi steel dissimilar metal joints by inertia radial friction welding. Int J Adv Manuf Technol 68(5–8):1479–1490. https://doi.org/10.1007/s00170-013-4936-7

    Article  Google Scholar 

  24. Jayabharath K, Ashfaq M, Venugopal P, Achar DRG (2007) Investigations on the continuous drive friction welding of sintered powder metallurgical (P/M) steel and wrought copper parts. Mater Sci Eng, A 454–455:114–123. https://doi.org/10.1016/j.msea.2006.11.026

    Article  Google Scholar 

  25. Ochi H, Kawai G, Yamamoto Y, Suga Y (2008) Tensile strength of friction-welded joints of copper alloys to steels . Proceedings of the Eighteenth International Offshore and Polar Engineering Conference Vancouver, BC, Canada, by The International Society of Offshore and Polar Engineers (ISOPE) ISBN 978–1–880653–70–8 (Set); ISBN 1–880653–68–0 (Set)

  26. Shen Z, Chen Y, Haghshenas M, Nguyen T, Galloway J, Gerlich AP (2015) Interfacial microstructure and properties of copper clad steel produced using friction stir welding versus gas metal arc welding. Mater Charact 104:1–9. https://doi.org/10.1016/j.matchar.2015.02.022

    Article  Google Scholar 

  27. Sokolov VI, Blinova AV, Ichev VY (1978) The mechanical properties of brazed joints in the 12KH18N10T steel and between the 12KH18N10T steel and copper M2 in the temperature range 298–4.2 K. Weld Prod 25(4):33–35

    Google Scholar 

  28. Nicholas ED, Jessop T, Dinsdale WO (1978) Friction welding dissimilar metals. Advances in welding processes proceedings, 4th international conference, Harrogate, York, May 1978. Weld Inst 49:23–36

    Google Scholar 

  29. Divagar S.R, Muthu Kumaran M (2015) Joining the different materials using friction welding. A review. Int J Mech Eng Rob Res 4(1):117–122. ISSN 2278–0149 www.ijmerr.com

  30. Kirik I, Balalan Z (2013) Weldability of AISI 304 to copper by friction welding. Mater Test 55(6):442–447. https://doi.org/10.3139/120.110456

    Article  Google Scholar 

  31. Maldonado C, Medina-Flores A, Béjar L, Mejía I (2004) T.H. North, nanoparticle and intermetallic formation in dissimilar friction welds produced with silver interlayers. Cambridge J Microsc Microanal 10(S02):568–569. https://doi.org/10.1017/S1431927604884253

    Article  Google Scholar 

  32. Lee WB, Kim YJ, Jung SB (2004) Effects of copper insert layer on the properties of friction welded joints between TiAl and AISI 4140 structural steel. Intermetallics 12(6):671–678. https://doi.org/10.1016/j.intermet.2004.02.004

    Article  Google Scholar 

  33. Ochi H, Ogawa K (2004) Friction welding using insert metal. Am Weld Soc-weld J 0036:1–6

    Google Scholar 

  34. Sassani F, Neelam JR (1988) Friction welging of incompatibles materials. Weld Res Suppl 265–270-s

  35. Bouarroud E, Bouzidi W, Menchi O, Abdi S (2009) Effects of copper powder insert layer on the properties of friction welded joints between AlCu and AISI 4140 structural steel. Defect Diffusion Forum 283–286:166–170. https://doi.org/10.4028/www.scientific.net/DDF.283-286.166

    Article  Google Scholar 

  36. Aritoshi M, Okita K (2003) Friction welding of dissimilar metals. Weld Int 17(4):271–275. https://doi.org/10.1533/wint.2003.3112

    Article  Google Scholar 

  37. Alves EP, Neto FP, An CY (2010) Welding of AA1050 aluminum with AISI 304 stainless steel by rotary friction welding process. J AerospTechnol Manag, São José dos Campos sep-dec 2010. 2(3):301–306. https://doi.org/10.5028/jatm.2010.02037110

  38. Meshram SD, Mohandas T, Reddy GM (2007) Friction welding of dissimilar pure metals. J Mater Process Technol 184(1–3):330–337. https://doi.org/10.1016/j.jmatprotec.2006.11.123

    Article  Google Scholar 

  39. Kubiszyn I, Pietras A (2003) Numerical modelling of the friction-welding process. Weld Int 17(6):425–430. https://doi.org/10.1533/wint.2003.3136

    Article  Google Scholar 

  40. Lindemann Z, Skalski K, Wlosinski W, Zimmerman J (2006) Thermo-mechanical phenomena in the process of friction welding of corundum ceramics and aluminium. Bull Polish Acad Sci Techn Sci 54(1):1–8

    Google Scholar 

  41. Bouarroudj E, Chikh S, Abdi S, Miroud D (2017) Thermal analysis during a rotational friction welding. Appl Therm Eng 110:1543–1553. https://doi.org/10.1016/j.applthermaleng.2016.09.067

    Article  Google Scholar 

  42. Satyanarayana VV, Reddy GM, Mohandas T (2004) Dissimilar metal friction welding of austenitic–ferritic stainless steels. J Mater Process Technol 160(2):128–137. https://doi.org/10.1016/j.jmatprotec.2004.05.017

    Article  Google Scholar 

  43. Marimuthu S, Balasubramanian KR, Kannan TTM (2021) Mechanical and surface morphology study of Monel – copper joint by rotary friction welding. Mater Today: Proceeding 37:419–424. https://doi.org/10.1016/j.matpr.2020.05.401

    Article  Google Scholar 

  44. Vyas HD, Mehta KP, Badheka V, Doshi B (2021) Friction welding of dissimilar joints copper-stainless steel pipe consist of 0.06 wall thickness to pipe diameter ratio. J Manuf Process 68:1176–1190. https://doi.org/10.1016/j.jmapro.2021.06.050

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. USTHB, Materials Science and Process Engineering Laboratory (LSGM), B.P. 32, El Alia, Bab Ezzouar, 16111, Alger, Algeria

    El-oualid Bouarroudj, Said Abdi & Djamel Miroud

Authors
  1. El-oualid Bouarroudj
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Said Abdi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Djamel Miroud
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

El-oualid Bouarroudj: conceptualization, experimental work, data curation, writing the article, software, investigation, reviewing and editing, methodology, analyzing all the obtained raw data and validation.

Said Abdi: supervision, project administration, methodology, validation and involved in the discussion, data curation and writing (original draft preparation), review and editing (final draft).

Djamel Miroud: realization of observations and analyzes on SEM.

Corresponding author

Correspondence to El-oualid Bouarroudj.

Ethics declarations

Ethics approval

This study complies with the ethical standards set out by Springer. All the authors read and approved the revised manuscript.

Conflict of interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Bouarroudj, Eo., Abdi, S. & Miroud, D. Improved performance of a heterogeneous weld joint of copper-steel AISI 1045 obtained by rotary friction using a metal powder insert. Int J Adv Manuf Technol 124, 1905–1924 (2023). https://doi.org/10.1007/s00170-022-10326-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10326-9

Keywords

Search

Navigation