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Friction-Assisted Dissimilar Solid State Lap Joining of Aluminum and Copper Pipes

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Abstract

The friction-assisted solid state lap joining process of dissimilar metal pipes is proposed by joining copper (Cu) and aluminum (Al) pipes. The joining process is designed to have two successive stages. In the first stage, the Cu pipe rotating with a mandrel rotates against the inner surface of the Al pipe. In the first stage, the relative rotation between the Cu and Al pipes breaks the oxide layers on the contacting surfaces and increases the temperature at the interface. In the second stage, as the area of the contact surface between the Cu and Al pipes increases due to the linear motion of the mandrel; as the mandrel begins to rotate alone against the Cu pipe, which now becomes stationary to induce diffusion bonding between the Cu and Al pipes. The results of microstructural analysis and mechanical testing show that solid state lap joining between the Cu and Al pipes for a light-weight heat exchanging component is successfully achieved. The microstructure evolution suggests that grain refinement by recrystallization occurs in the joining region for both the Cu and Al sides.

Highlights

  • The performance of friction-assisted solid state lap joining between dissimilar pipes is identified through experiment

  • A custom-made pneumatic press device was designed to realize the suggested solid state joining method

  • The joint quality was confirmed by microstructure analysis and mechanical testing

  • Aluminum base metal fracture was observed during tensile test

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Acknowledgements

This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government (MSIT) (No. 2020R1A5A6017701). This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government (MSIT) (No. 2019R1A2C2009939, 2021R1A2C3005096).

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Authors and Affiliations

  1. School of Mechanical Engineering, University of Ulsan, Ulsan, 44610, Republic of Korea

    Ji-Won Kang, Shengwei Zhang, Tu-Anh Bui Thi & Sung-Tae Hong

  2. Naval Architecture and Ocean Engineering College, Dalian Maritime University, Dalian, 116026, China

    Shengwei Zhang

  3. Department of Materials Science & Engineering and Center for Iron & Steel Research, Seoul National University, Seoul, 08826, Republic of Korea

    Siwhan Lee & Heung Nam Han

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  1. Ji-Won Kang
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Correspondence to Sung-Tae Hong.

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Kang, JW., Zhang, S., Bui Thi, TA. et al. Friction-Assisted Dissimilar Solid State Lap Joining of Aluminum and Copper Pipes. Int. J. Precis. Eng. Manuf. 24, 199–208 (2023). https://doi.org/10.1007/s12541-022-00745-9

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  • DOI: https://doi.org/10.1007/s12541-022-00745-9

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