Abstract
In the present investigation, two different tool designs along with different process parameters such as tool pin offset, welding speed and axial plunge load were used to produce dissimilar copper to aluminium (6061-T651) friction stir welding joints. Macrostructure and microstructure analysis, tensile test, hardness measurement test, scattered electron microscopy and electron-dispersive tests were performed to evaluate the weldability and weld properties of dissimilar copper–aluminium joints. The results revealed that defect-free dissimilar friction stir welding was achieved using a cylindrical tool pin profile. On the other hand, the taper tool pin profile was not found to be suitable for dissimilar friction stir welding system (FSW). Maximum tensile strength of 133 MPa and hardness of 181 HV (in the nugget zone) were obtained when FSW process parameters such as rotational speed, welding speed, tilt angle, tool pin offset and tool pin profile were kept at 1500 rpm, 40 mm/min, 2°, 2 mm and cylindrical profile, respectively. Axial plunge load value depended on the shoulder diameter as well as on the tilt angle. Axial plunge load range from 600 to 700 kgf was used to achieve defect-free copper to AA6061-T651 (of 6.3 mm in thickness) friction stir welded joint.
Similar content being viewed by others
References
Sahin M (2010) Joining of aluminium and copper materials with friction welding. Int J Adv Manuf Technol 49:527–534
Al-Roubaiy A-O, Nabat SM, Batako A-DL (2014) Experimental and theoretical analysis of friction stir welding of Al–Cu joints. Int J Adv Manuf Technol 71:1631–1642
Liu HJ, Shen JJ, Zhou L, Zhao YQ, Liu C, Kuang LY (2011) Microstructural characterisation and mechanical properties of friction stir welded joints of aluminium alloy to copper. Sci Technol Weld Join 16:92–99
Liu HJ, Shen JJ, Xie S, Huang YX, Cui F, Liu C, Kuang LY (2012) Weld appearance and microstructural characteristics of friction stir butt barrier welded joints of aluminium alloy to copper. Sci Technol Weld Join 17:104–110
Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R 50:1–110
Rai R, De A, Bhadeshia HKD, DebRoy T (2011) Review: friction stir welding tools. Sci Technol Weld Join 16(4):325–342
Li JQ, Liu HJ (2013) Design of tool system for the external non rotational shoulder assisted friction stir welding and its experimental validations on 2219-T6 aluminum alloy. Int J Adv Manuf Technol 66:623–634
Ouyang J, Yarrapareddy E, Kovacevic R (2006) Microstructural evolution in the friction stir welded 6061 aluminum alloy (T6-temper condition) to copper. J Mater Process Technol 172:110–122
Xue P, Xiao BL, Ni DR, Ma ZY (2010) Enhanced mechanical properties of friction stir welded dissimilar Al–Cu joint by intermetallic compounds. Mater Sci Eng A 527:5723–5727
Xue P, Ni DR, Wang D, Xiao BL, Ma ZY (2011) Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al–Cu joints. Mater Sci Eng A 528:4683–4689
Akinlabi ET (2011) Effect of shoulder size on weld properties of dissimilar metal friction stir welds. J Mater Eng Perform 21:1514–1519
Galvao I, Leal RM, Loureiro A, Rodrigues DM (2010) Material flow in heterogeneous friction stir welding of aluminum and copper thin sheets. Sci Technol Weld Join 15:654–660
Galvao I, Oliveira JC, Loureiro A, Rodrigues DM (2011) Formation and distribution of brittle structures in friction stir welding of aluminium and copper: influence of process parameters. Sci Technol Weld Join 16:681–689
Saeid T, Zadeh AA, Sazgari B (2010) Weldability and mechanical properties of dissimilar aluminum–copper lap joints made by friction stir welding. J Alloys Compd 490:652–655
Zadeh AA, Saeid T, Sazgari B (2008) Microstructural and mechanical properties of friction stir welded aluminum/copper lap joints. J Alloys Compd 460:535–538
Esmaeili A, Zareie Rajani HR, Sharbati M, Besharati Givi MK, Shamanian M (2011) The role of rotation speed on intermetallic compounds formation and mechanical behaviour of friction stir welded brass/aluminum 1050 couple. Intermetallics 19:1711–1719
Akinlabi ET, Els-Botes A, McGrath PJ (2011) Effect of travel speed on joint properties of dissimilar metal friction stir welds. Second International Conference on Advances in Engineering and Technology 155–161
Firouzdor V, Kou S (2012) Al-to-Cu friction stir lap welding. Metall Mater Trans 43a:303–315
Genevois C, Girard M, Huneau B, Sauvage X, Racineux G (2011) Interfacial reaction during friction stir welding of Al and Cu. Metall Mater Trans 42a:2290–2295
Pande SV, Badheka VJ (2014) Effect of tool pin offset on mechanical and metallurgical properties of dissimilar FSW joints of 6061T6 Al alloy to copper material. Indian Weld J 47(3):68–74
Mehta KP, Badheka VJ (2014) Effects of tilt angle on properties of dissimilar friction stir welding copper to aluminum. Mater Manuf Process. doi:10.1080/10426914.2014.994754
Mehta KP, Badheka VJ (2014) Investigations on friction stir welding defects for dissimilar copper to aluminum materials under different process parameters. Proceedings of International Conference on Friction Based Processes, IISc-Bangalore, India
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Mehta, K.P., Badheka, V.J. Influence of tool design and process parameters on dissimilar friction stir welding of copper to AA6061-T651 joints. Int J Adv Manuf Technol 80, 2073–2082 (2015). https://doi.org/10.1007/s00170-015-7176-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7176-1