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Effect of welding speed on micro-friction stir lap welding of ultra-thin aluminium and copper sheets

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Abstract

In this work, the technical feasibility of micro-friction stir lap welding to join 0.5-mm ultra-thin aluminium and copper sheets was studied. After identifying the processability windows of important parameters such as plunge depth, welding speed and material positioning, the effect of welding speed to join the ultra-thin AA5052 and C11000 sheets was assessed. Welding speeds were varied from 50 to 400 mm/min. The relationship of the welding speed to the joint quality, such as microstructure, tensile lap shear strength, weld surface roughness and joint electrical resistance was elucidated. It was found that the dissimilar sheets only joined when the copper sheet was placed on top of the aluminium sheet. Feasible welding was found at welding speeds of 50 mm/min and 70 mm/min, a constant rotational speed of 1500 rpm and a plunge depth of 0.55 mm. The welds possessed similar average tensile lap shear strength of 16 to 18 MPa but differed in microstructure and joint electrical resistance. More visible stir zones with lamella bands were found in the microstructure of welds produced at 50 mm/min, indicating a higher degree of mixing, albeit with excessive flashes and tunnel defects near the joint interface. On the other hand, the welds produced at 70 mm/min exhibited limited mixing and lamellar intermetallic compounds. Tunnel defects were mostly at the advancing side within the copper layer, and hook defects were absent. With selected processing parameters, micro-friction stir welding ultra-thin copper sheets to aluminium sheets is demonstrably feasible for less critical applications.

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Data availability

The datasets generated during and/or analysed during the current study are available from the corresponding author upon reasonable request.

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Funding

This work has received financial support from the Ministry of Higher Education Malaysia through the Fundamental Research Grant Scheme (Grant No: FRGS/1/2022/TK10/MMU/02/10).

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Authors and Affiliations

  1. Centre for Advanced Mechanical and Green Technology, Faculty of Engineering and Technology, Multimedia University, Jalan Ayer Keroh Lama, Bukit Beruang, 75450, Melaka, Malaysia

    Moumen Mahmoud Jazayerli, Chee Kuang Kok, Kia Wang Por & Kia Wai Liew

  2. Fakulti Teknologi Dan Kejuruteraan Industri Dan Pembuatan, Universiti Teknikal Malaysia Melaka, 76100 Durian Tunggal, Melaka, Malaysia

    Kamil Sued

  3. Motorola Solutions (M) Sdn. Bhd, Plot 2A, Medan Bayan Lepas, Bayan Lepas Technoplex, 11900 Bayan Lepas, Pulau Pinang, Malaysia

    Chin Chin Ooi

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  1. Moumen Mahmoud Jazayerli
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  2. Chee Kuang Kok
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  3. Kamil Sued
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  4. Kia Wang Por
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Correspondence to Chee Kuang Kok.

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Jazayerli, M.M., Kok, C.K., Sued, K. et al. Effect of welding speed on micro-friction stir lap welding of ultra-thin aluminium and copper sheets. Weld World (2024). https://doi.org/10.1007/s40194-024-01761-1

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