Dissimilar friction stir welding of Al to non-Al metallic materials : an overview

The paper presents a comprehensive review on dissimilar friction stir welding (FSW) of Al to non-Al metallic materials, wherein the combination of Al–Mg, Al–Cu, Al-steel and Al–Ti are covered. The summary revealed that FSW is observed as one of the most feasible solutions in the family of welding in case of dissimilar materials combinations of Al to non-Al metallic materials. The challenges such as the formation of intermetallic compounds, defects, and degradation of mechanical properties at the joint area are extensively managed in the case of dissimilar FSW compared to dissimilar conventional welding

Influence of copper plate positioning, zero tool offset, and bed conditions in friction stir welding of dissimilar Al-Cu alloys with different thicknesses

Publisher Copyright: © 2022 CIRPFriction stir welding of dissimilar thickness aluminum and copper alloys was carried out without offsets by placing the copper at different positions, with horizontal and inclined bed conditions. The influence of the copper plate positions and bed conditions on macro-structure, microstructure, and mechanical properties were investigated. Optical microscopy, FE-SEM, EBSD, Tensile test, bending test, micro-hardness, and XRD analysis were carried out to understand the joint formation mechanism. The joint efficiency of 90% and 80.08% and bending angles of 93˚ and 35˚ were obtained, respectively, when the copper was placed at the middle position with horizontal and inclined bed conditions.Peer reviewe

Dissimilar friction stir welding of Al to non-Al metallic materials : An overview

Publisher Copyright: © 2022 Elsevier B.V.The paper presents a comprehensive review on dissimilar friction stir welding (FSW) of Al to non-Al metallic materials, wherein the combination of Al–Mg, Al–Cu, Al-steel and Al–Ti are covered. The summary revealed that FSW is observed as one of the most feasible solutions in the family of welding in case of dissimilar materials combinations of Al to non-Al metallic materials. The challenges such as the formation of intermetallic compounds, defects, and degradation of mechanical properties at the joint area are extensively managed in the case of dissimilar FSW compared to dissimilar conventional welding.Peer reviewe

Joint strength evaluation of friction stir welded Al-Cu dissimilar alloys

Friction stir welding has been successfully employed to fabricate dissimilar thickness AA1050 and oxygen free copper (Cu-OF). The highest value of the joint tensile strength obtained was 91% of the AA1050 alloy strength with the tensile fracture path on the aluminum side. At the Al-Cu interfacial microstructure, a layer of Al4Cu9 and Al2Cu intermetallic compounds (IMCs) with thickness of 2.2 μm–0.26 μm was developed at different welding speeds. The voluminous IMCs have an adverse impact on the tensile characteristics of the joint. The IMCs (0.26 μm−0.77 μm) at welding speeds of 160 mm/min and 213 mm/min with 1 mm tool offset, has trivial effect on the tensile property. The mechanical property of the joint was significantly affected by the tool offset and welding speed. Image processing techniques such as Gaussian blur, histogram normalization and binarisation were utilized to understand the distribution of copper in the weld stir zone.Peer reviewe