Experimental investigation on mechanical properties affected by dissimilar friction stir spot welding of aluminum 6061-T6 alloy to copper

Document Type : Original Article

Authors

1 Associate Professor, Department of Mechanical Engineering, Faculty of Engineering, University of Zanjan, Zanjan, Iran

2 MSc Graduate, Department of Mechanical Engineering, Faculty of Engineering, University of Zanjan, Zanjan, Iran

3 PhD Student, Department of Mechanical Engineering, Faculty of Engineering, University of Zanjan, Zanjan, Iran

10.22034/ijme.2023.413891.1824

Abstract

Friction stir spot welding (FSSW) is one of the types of solid state welding methods for joining parts and light metals, especially aluminum and copper alloys. In this research, the effect of important parameters of the FSSW welding process, such as rotational speed and tool stop time, on the mechanical and micro- hardness properties of dissimilar connections of aluminum alloy 6061 to commercial pure copper has been investigated. Also, the effect of the placement of the sheets on the mechanical properties has been studied. The results show that by increasing the rotational speed of the tool from 1250 to 1600 rpm and the stopping time of the tool from 5 to 10 seconds, the tensile and bending strength of all welded samples increases. Also, at rotational speeds less than 1250 rpm due to the reduction of frictional heat generation, and higher than 1600 rpm due to excessive heat generation, the quality of connections has decreased. The results of micro- hardness measurement show that in various welding parameters, increasing the rotational speed and stopping time of the tool caused the creation of fine grains and recrystallization found in the stir zone and other areas, which is due to the heat produced due to friction and severe material change in shape. The obtained results show that at high aluminum and low copper, the yield strength and ultimate tensile strength reach their highest value, of 142 MPa and 188 MPa respectively.

Keywords

References

[1] Ahmed M A, Ahmed A H, Ali A A. Microstructure and mechanical properties of dissimilar aluminum alloy joints by friction stir welding. Journal of Materials Engineering and Performance. 2020. 29:4845– 4856. doi: 10.3390/met11010128
[2] Kummari S R, Prasad S S, Murty B S. Mechanical and metallurgical characterization of dissimilar Al alloys joints produced by friction stir welding. Journal of Materials Research and Technology. 2021. 10:24–34. doi: 10.1016/j.matdes.2008.04.042
[3] Kumar R, Kumar A, Kumar A, Kumar V. Effect of rotational speed on microstructure and mechanical properties of dissimilar aluminum alloys AA6061-T6 and AA7075-T6 friction stir spot welded joints. Journal of Manufacturing Processes. 2021. 62:185–192. doi: 10.1007/s13632-016-0315-8
[4] Manickam S, Rajendran C, Ragu S, Sivamaran V, Balasubramanian V. Assessment of the influence of FSSW parameters on shear strength of dissimilar materials joint (AA6061/AZ31B). International Journal of Lightweight Materials and Manufacture. 2023. 6:33– 45. doi: 10.1016/j.ijlmm.2022.07.005
[5] Tankoua AT, Kohler T, Bergmann J P, Gratzel M, Betz P, Lindenau D. Tool downscaling effects on the friction stir spot welding process and properties of current-carrying welded aluminum-copper joints for e-mobility applications. Metals. 2021. 11:1-20. doi: 10.3390/met11121949
[6] Yangfan Z, Wenya L, Xiawei Y, Yu S, Qiang C, Zhikang S. Microstructure and mechanical properties of refill friction stir spot welded joints: Effects of tool size and welding parameters, journal of material research and technology. 2022. 21:5066- 5080. doi: 10.1016/j.jmrt.2022.11.108
[7] Gera D, Fu B, Suhuddin U, Plaine A, Alcantara N, dos S F. Microstructure, mechanical and functional properties of refill friction stir spot welds on multilayered aluminum foils for battery application. J Mater Res Technol. 2021. 13:2272-2286. doi: 10.1016/j.jmrt.2021.06.017
[8] Paidar M, Khodabandeh A, Najafi A. Effects of the tool rotational speed and shoulder penetration depth on mechanical properties and failure modes of friction stir spot welds of aluminum 2024-T3 sheets. Journal of Mechanical Science and Technology. 2014. 12:4893–4898. doi: 10.1007/s12206-014-1108-0
[9] Zhikang S, Yuquan D, Adrian P. Advances in friction stir spot welding. Critical Reviews in Solid State and Materials Sciences. 2020. 9:457- 534. doi: 10.1080/10408436.2019.1671799
[10] Vidyasagar S. Balaji A, Sharif S, Uthayakumar R. Influence of multi-pass friction stir spot welding on microstructure and mechanical properties of dissimilar aluminum alloy joints. Journal of Materials Research and Technology. 2021. 10:449 459. doi: 10.1016/j.jalmes.2023.100010
[11] Zhang H. Effect of tool plunge depth on the microstructure and fracture behavior of refill friction stir spot welded AZ91 magnesium alloy joints. International Journal of Minerals, Metallurgy and Materials. 2021. 28:699–709. doi: 10.1007/s12613-020-2044-x
[12] Li M, Zhang C, Wang D, Zhou L, Wellmann D, Tian Y. Friction stir spot welding of aluminum and copper. A review. Materials. 2020. 13:156- 164. doi: 10.3390/ma13010156
[13] Hussein A M A, Ali A M M, Serry M S A, Alaskari A M. Influence of tool traverse speed and rotational speed on the mechanical properties and microstructure of dissimilar AA6061-T6 and AA7075-T6 friction stir spot welded joints. Journal of Materials Research and Technology. 2020. 9:9781–9791. doi: 10.1177/09544089221080823
[14] Akinlabi E T, Osinubi A S, Madushele N, Akinlabi S A, Ikumapayi O M. Data on micro hardness and structural analysis of friction stir spot welded lap joints of AA5083-H116, Data in Brief. 2020. 33:106- 118. doi: 10.1016/j.dib.2020.106585
[15] Liu H, Ma L, Gong P, Dong J, Yue Y. Friction stir spot welding of Al- Cu with different Zn foils. Transactions of the Indian Institute of Metals. 2022. 2:56- 66. doi: 10.1007/s12666-022-02792-2
[16] Hou W, Shen Z, Huda N, Oheil M, Shen Y, Jahed H. Enhancing metallurgical and mechanical properties of friction stir butt welded joints of Al- Cu via cold sprayed Ni interlayer. Materials Science and Engineering. 2021. 5:809- 821. doi: 10.1016/j.msea.2021.140992
[17] Chen D, Li J L, Xiong J T, Shi J M, Dou J X, Zhao H X. Enhance mechanical properties of refill friction stir spot welding joint of allay 7050/2524 aluminum via suspension rotating process. Journal of Materials Research and Technology. 2021. 12:1243-1251. doi: 10.1016/j.jmrt.2021.03.067
[18] Venukumar S. Baby B, Muthukumaran S, Kailas S V. Microstructural and Mechanical Properties of Walking Friction Stir Spot Welded AA 6061-T6 Sheets, Procedia Materials Science. 2014. 6:656- 665. doi: 10.1016/j.mspro.2014.07.081
[19] ASTM-E8, Standard Mechanical testing and Evaluation Tensile testing. American Society for Testing and Material. 2000.
[20] ASTM-E290, Standard test method for Bend testing of material for ductility. American Society for Testing and Material. 1998.
[21] ASTM-E384, Standard test method for micro- hardness of materials, American Society for Testing and Material. 2008.
[22] Bilici M, Hunt F. The optimization of welding parameters for friction spot welding of high-density polyethylene sheets. Materials and Design. 2009. 7:4074-4079. doi: 10.1016/j.matdes.2011.03.014
[23] Tozaki Y, Uematsu Y, Tokaji K. Effect of tool geometry on microstructure and static strength in friction stir spot welded aluminum alloys. International Journal of Machine Tools and Manufacture. 2007. 11:2230-2236. doi: 10.1016/j.ijmachtools.2007.07.005
[24] Tran V, Pan J, Pan T. Effects of processing time on strengths and failure modes of dissimilar spot friction welds between aluminum 5754-O and 7075-T6 sheets. Journal of materials processing technology. 2009. 8: 3724-3739. doi: 10.1016/j.jmatprotec.2008.08.028

Files

Share

How to cite

Statistics