The present study investigates the feasibility of producing strong and defect-free joints between 1050 aluminum and pure copper sheets by micro-friction stir welding using traditional and new tools. Many variables affect the quality of these types of joints that the parameters of rotational speed, welding speed, and tool offset are considered the main variables. The Taguchi method and analysis of variance were used to design the experiments and evaluate the obtained results. By analyzing the results of the tensile test and signal-to-noise analysis, the average maximum ultimate tensile strength of the joints is reported to be 88 MPa, when using the parameters of rotational speed, welding speed, and offset of the tool with levels of 2400 rpm, 40 mm/min, and 0.25 mm. The analysis of variance also showed that the parameters of rotational speed and welding speed, respectively, had the most significant effect on the tensile strength of the joints. The maximum and minimum values obtained from the microhardness test were recorded for the weld nugget zone and the heat-affected zone of aluminum, respectively, which are equal to 192 HV and 21 HV. Also, by performing sanding operations, the roughness of the joints is significantly reduced. The x-ray diffraction test results on optimal samples showed the presence of intermetallic compounds CuAl2 and Cu9Al4 in the welding area. The tensile strength of the joints created is strongly dependent on the formation of these intermetallic compounds.
#1Davood Rahmatabadi(IUST: Iran University of Science and Technology)H-Index: 11
#2Moslem Tayyebi(SUTECH: Shiraz University of Technology)H-Index: 9
Last. Majid Rajabi(IUST: Iran University of Science and Technology)H-Index: 11
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In this article, the influences of ultrasonic vibrations and post-annealing on the formability of multilayered Al5052/MgAZ31B composite were evaluated experimentally. Accordingly, a multilayered Al...
#1Chia-Hung Hung(Missouri University of Science and Technology)H-Index: 2
The success of laser-foil-printing (LFP) additive manufacturing depends critically on the laser welding of sheet metals onto the substrate or the previous layer during the part fabrication process. The welding can be generally categorized into two modes: conduction mode and keyhole mode. In this study, 304L stainless steel parts fabricated by the LFP process using the two laser welding modes are compared. The porosity, microstructure, and tensile properties of the fabricated parts in these two m...
Abstract In this study, dissimilar butt joints of 1.0 mm thick 6061-T6 aluminum alloy and T2 pure copper ultra-thin sheets were fabricated using micro friction stir welding under various tool traverse speeds while the rotational speed was 3000 rpm. The results indicated that the reliable metallurgical bonding was achieved at Al/Cu interface, which can be attributed to the formation of continuous Al2Cu-AlCu-Al4Cu9 intermetallic compounds (IMCs) layer. A large portion of Cu particles consisting of...
#2Huijie Liu(HIT: Harbin Institute of Technology)H-Index: 17
Last. Shao-hua Luo(NU: Northeastern University)H-Index: 1
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The 1-mm-thick Al to Cu friction stir welding is successfully performed at the tool offsets toward Al side ranging from 0 to 2 mm. With increasing tool offset, the phenomenon of material sticking to tool shoulder surface is restricted and the area of Al–Cu mixing zone is reduced progressively. As the tool offset is increased from 0 to 1 mm, the weld shows a variation of intermetallic phases from CuAl2 + Cu9Al4 to CuAl2 and exhibits a lowering in hardness and tensile properties. The 2-mm-offset w...
#1N. Najafizadeh(IUST: Iran University of Science and Technology)H-Index: 1
#2Majid Rajabi(IUST: Iran University of Science and Technology)H-Index: 11
Last. Saeid Amini(University of Kashan)H-Index: 20
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Ultrasonic energy is used for applying severe plastic deformation on metal surfaces. In the present work, the effect of ultrasonic vibration on the formability, microhardness and microstructural properties of St14 steel sheet has been investigated. To be precise, a semi-hemispherical-head forming tool had shaped the specimens until the necking started to happen. Conventional as well as the ultrasonic-assisted biaxial stretch forming test has been performed on St14 steel sheets and obtained data ...
Friction Stir Welding (FSW) is a solid-state welding process used for welding similar and dissimilar materials. FSW is especially suitable to join sheet Al alloys, and this technique allows different material couples to be welded continuously. In this study, 1050 Al alloys and commercially pure Cu were produced at three different tool rotation speeds (630, 1330, 2440 rpm) and three different tool traverse speeds (20, 30, 50 mm/min) with four different tool position (0, 1, 1.5, 2 mm) by friction ...
The status quo of aluminium-to-copper joining by friction stir welding (FSW) drastically changed in recent years, as a result of the increased interest of the scientific community on this subject. Actually, since 2006 a large increase in the number of research groups addressing Al–Cu FSW has been witnessed all over the world, together with a significant increase in the amount of published studies. A chronological perspective on the evolution in Al–Cu FSW research is provided in this work, highli...
The advent of friction stir welding (FSW) in 1991 has been evolutionary in the joining of metals and related materials. Friction stir welding has enabled the joining of metals that could not be joined by other welding processes. Research has shown that dissimilar materials with very different properties, plastics, composites and even wood can be joined by FSW. Recent activities in the application of FSW has seen the development of micro friction stir welding (μFSW), which is the FSW of very thin...
#2V. Jayabalan(College of Engineering, Guindy)H-Index: 2
Abstract Friction stir welding of aluminum and copper were carried out by varying the tool travel speed from 50 mm/min to 90 mm/min. The joint properties were evaluated and characterized with respect to the stir zone formation, intermetallics formation and its distribution. Tool traverse speed of 70 mm/min and 80 mm/min resulted in the optimum range of heat input to form defect free stir zone. The reduced diffusion rate and time prevailing at tool traverse speed of 80 mm/min resulted in lower in...
In this study, AA 1050 aluminum alloy and commercially pure copper in annealed and severely plastic deformed conditions were used. The technique used for imposing the severe strain to the sheets was constrained groove pressing (CGP) process. The annealed and severely plastic deformed sheets were subjected to friction stir welding (FSW) at different rotation and traverse speeds. Cu was placed in advancing side. Constant offset of approximately 1 mm was used toward Al side for all welds. A range o...
Laser-Powder Bed Fusion (LPBF) has been extensively utilized by a broad range of manufacturing industries in recent years. Fabricating parts with high mechanical properties and smooth surfaces has motivated such industries and academic communities to study different aspects and steps of the LPBF process, including powder spreading, laser scanning, and solidification. Creation of highly dense powder layers with lower surface roughness before laser scanning step is a must for producing non-porose ...
