Microstructures at Interface Regions and Fracture Behavior of Friction Stir Lap Welding of Al-Cu
Journal Title: International Journal for Research in Applied Science and Engineering Technology (IJRASET) - Year 2017, Vol 5, Issue 6
Abstract
Friction Stir Welding (FSW) is a relatively new solid state joining technique, which is used not only for joining the aluminum and its alloys but also has potential for joining dissimilar metals with very different physical and mechanical properties that are hard to weld using conventional fusion welding processes. There have been a reasonable number of studies in the literature on microstructure and fracture behavior under static loading and very few studies on cyclic loading of FSW of Al 6060-T5 and copper. However, a better scientific understanding in a number of aspects is required. This include interface phenomena during FSW of Al 6060-T5 with copper with large differences in melting temperatures, how exactly the microstructure in the interfacial region is related to fracture behavior when subjected to static loading is far from being fully understood. Thus, this study aims to understand the uncertainty about the optimum or best pin position (Dp) for friction stir lap welding (FSLW) of Al-Cu, so that weld samples can achieve the highest attainable load during tensile-shear testing, tests were conducted to investigate the maximum tensile-shear load an Al-Cu FSLW sample of a set width (Fm/Ws) can withstand before fracture depends on the pin positioning related microstructures in the weld interface region. Interface microstructures differ depending on whether or not the tool pin penetrates the lapping interface. It has been found that Fm/Ws values of the defect free weld samples vary quite significantly and in general are significantly higher than those reported in the literature. When the pin penetration is close to zero no intermetallic layers were formed, hence value of Fm/Ws was zero. When the pin penetration is 0.4mm during FSLW and thus the commonly observed a thin Al–Cu interface layer forms and this layer does not grow beyond 500 nm. It will be shown that the thin interfacial layer can withstand a high tensile-shear load and thus the adjacent Al material shears to fracture. When the pin penetrates more than 0.4mm during FSLW and thus the commonly observed mix stir zone (MSZ) forms, values of Fm/Ws are lower than that of 0.4mm pin penetration welds but remain quite high.
Authors and Affiliations
Shubhavardhan R N
Keywords
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