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Electrical and mechanical properties of friction stir welded Al-Cu butt joints

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Abstract

Friction stir welding (FSW) is a suitable method for producing dissimilar joints. This study investigated the electrical and mechanical properties of friction stir welded aluminium-copper joints that were manufactured at a comparatively high welding speed of 500 mm/min. For this purpose, the specimens welded in a butt joint configuration were subjected to metallographic analyses, tensile testing, electrical resistance measurements and also combined fatigue and resistance testing. The tensile strength of the examined specimens was 110 MPa, which is similar to the aluminium-base material strength. The electrical resistance of the friction stir welds was between the electrical resistances of the base materials copper and aluminium. The fatigue tests were discontinued after 2 × 106 cycles. Fatigue testing resulted in a survival probability of 90% for this number of cycles and a maximum stress of 49 MPa at a stress ratio of R = 0.1. The electrical resistance of the examined joints remained practically constant during the fatigue test until specimen failure occurred.

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Authors and Affiliations

  1. Volkswagen AG, Corporate Research, Berliner Ring 2, 38440, Wolfsburg, Germany

    N. Eslami, A. Harms, B. Henke & A. Fricke

  2. Department for Cutting and Joining Manufacturing Processes, University of Kassel, Kurt-Wolters-Str. 3, 34125, Kassel, Germany

    S. Böhm

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  1. N. Eslami
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  2. A. Harms
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  3. B. Henke
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  4. A. Fricke
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  5. S. Böhm
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Correspondence to N. Eslami.

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Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

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Eslami, N., Harms, A., Henke, B. et al. Electrical and mechanical properties of friction stir welded Al-Cu butt joints. Weld World 63, 903–911 (2019). https://doi.org/10.1007/s40194-019-00719-y

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  • DOI: https://doi.org/10.1007/s40194-019-00719-y

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