YOU ARE DOWNLOADING DOCUMENT

Please tick the box to continue:

Transcript
Page 1: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

A Brief Review of Friction Stir Welding Between Dissimilar Aluminium

Alloy and Pure Copper

1Pratikrajsinh Gohil,2Unnati Joshi,3Tejas Vyas

123Department of Mechanical Engineering,1PG Student,2Associate Professor,

3Assistant Professor

123 Parul Institute of Technology, Vadodara, Gujarat

[email protected]

Abstract

Friction Stir Welding (FSW) is a solid state welding process capable of welding dissimilar materials such as aluminum and copper having wide range of industrial applications. The welding process is

widely used because it produces quality welds with good joint strength exhibiting none or a few amount

of intermetallic compounds. Copper and aluminum dissimilar joining is important for taking advantage of properties of both the materials such as electrical conductivity, thermal conductivity and corrosion

resistance. In this paper we review the research work done in past between aluminum and copper

joining by friction stir welding with a focus on resulting weld mechanical properties and microstructure

by optimization of the process parameters and FSW tool pin positioning such as tool pin offset, tool tilt angle and tool design features with a view for dissimilar aluminum and copper joining. It also includes

the future research in this field of welding.

Keywords – Friction stir welding, aluminium, copper, dissimilar materials, optimization, mechanical

properties and microstructure.

I. INTRODUCTION

Producing a good quality weld between dissimilar materials such as copper and aluminium with a good

joint strength is a challenging and complicated task for researchers and engineers. In the current

competitive world of industrial development that need requirement of different and various properties in a

single component or a part that can only be fulfilled by the effective joining of two dissimilar materials.

Aluminium and copper possess good electrical conductivity, thermal conductivity and corrosion

resistance that make them applicable for producing parts or components that require good electrical and

thermal conductivity for its application. Friction stir welding is an effective solid state welding technique

that can efficiently produce a good quality weld between the dissimilar materials. The capability of

friction stir welding to join separate dissimilar materials without melting is a unique feature of friction stir

welding. Friction Stir Welding (FSW) is a solid–state joining technique invented by The Welding

Institute (TWI) in 1991 for welding of ferrous and non–ferrous metals. Recently the technique is also

used for welding of polymer materials as well as welding between a metallic material and polymer. FSW

has developed as a huge improvement in metal joining in recent decade and is capable of welding

materials such as aluminium alloys, copper alloys, titanium alloys, mild steel, stainless steel and

magnesium alloys.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org191

Page 2: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

A) Principle of operation.

Friction stir welding employs a non consumable rotating welding tool that has a probe or a pin that

extends below a shoulder which is fully penetrated between the two adjacent mating surfaces of the

workpieces as shown in fig 1. As the tool is traversed along the joint line, it mechanically pressurizes and

forges the two pieces of metal. Heat is formed by the friction between the revolving tool and the

workpiece material, which develops a soft region near the FSW tool of metal, and forges the hot and

softened metal by the mechanical pressure. Stirring of the tool along the joint line in traverse direction

uniformly joins the two edges of the adjacent workpieces as a result of welding. Advancing sides and the

retreating sides are the two different sides of the two work samples.

Fig. 1 Principle of operation of FSW [1]

B) FSW Tool

The FSW tool plays a significant and vital role for effective joining and leading the material flow

along the joint line along the traverse direction. The FSW tool consists of three parts: a shank,

shoulder and the pin or a probe with shoulder and pin the main parts of the tool as the shoulder

makes full contact on the upper surface of the interface at the joint line with the pin which is fully

inserted into the workpiece. Different tool design and geometry exhibit different mechanical

properties and microstructure of the welded joint due to the variation in tool geometry and is

majorly responsible for quality of weld. Thus the FSW tool is better known as the heart of the

joining process.

The following are the different types of tools used in friction stir welding are:

1) Straight Cylindrical

2) Threaded Cylindrical

3) Tapered Cylindrical

4) Square

5) Triangle

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org192

Page 3: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

Fig.2 Basic FSW tool pin profiles [2] Fig.3. Schematic View of FSW Tool [3]

C) Friction stir welding process parameters :

Tool rotation and traverse speeds

There are two types of tool speeds in friction-stir welding process as the velocity at which the tool

rotates and velocity at which it moves or traverses down the interface. The above two parameters

have significant importance and must be chosen with care to make sure a successful and efficient

welding cycle. The relationship between the rotation speed, the welding speed and the heat input

during welding is complex but it can be said that increasing the rotation speed or decreasing the

traverse speed will result in a hot weld.

Tool tilt and plunge depth

The plunge depth is defined as the depth of the lowest point of the shoulder below the

surface of the welded plate and has been seen as a basic parameter for guaranteeing weld

quality. As we plunge the shoulder below the plate surface it increase the pressure

beneath the tool and helps ensure adequate forging of the material. As we tilt the tool by

2–4 degrees, such that the rear of the tool is lower than the front, has been found to assist

the weld bonding for good joint strength for dissimilar FSW of aluminium and copper

Tool pin offset

The tool pin offset is defined as the offset of the tool pin from the weld centerline towards a

particular base material. Zero tool pin offset means the welding tool axis is exactly at the

centerline of the interface between the two welded work samples. It is recommended that the

conventional method of FSW welding where pin is inserted at the weld centre line produced poor

and imperfect joints in dissimilar FSW [4, 5,6,7,8]

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org193

Page 4: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

II. PAST STUDIES ON FRICTION STIR WELDING BETWEEN ALUMINIUM

ALLOYS AND COPPER

A. Optimization of the process parameters

In a developing field of dissimilar material welding optimization will be considered as a

significant technique to improve its application fields. Optimization deals with obtaining

process parameters accurately to certain value from a series of values having long range. So

accurate value achievement will reduce cost and also develop and improve its output

parameters

Sachindra Shankar et al.[9] conducted friction stir welding of aluminium alloy 1050 to pure

copper joint by varying two values of rotational speed such as 1400 rpm and 2000 rpm and

two values of traverse speed such as 40 and 63 mm/min with 2mm tool pin offset and keeping

all the other parameters such as tool design and geometry and tool tilt angle as constant.

Mechanical tests such as tensile test, microhardness tests and FESEM tests were implemented

to inspect the joint strength and microstructural property respectively. It was concluded that

the optimum set of parameters include the tool rotational speed of 1400 rpm and tool traverse

speed of 63 mm/min fabricated defect free welded joints. Highest joint strength acquired was

approximately 91% of Al parent metal in weld nugget by taking the 2 mm offset of the tool

on the Al side and fine-grained microstructure was observed in the weld nugget

Nitish kumar et al. [10] evaluated tensile strength in friction stir welded aluminum alloy

6101-T6 and commercially pure copper joints by conducting an experimental study to

optimize the critical process parameters such as tool geometry, shoulder diameter to pin

diameter ratio, welding speed, rotational speed and pin offset on the tensile behavior of

friction stir welded between aluminum alloy 6101-T6 and commercially used pure copper

using Taguchi’s L 16 design of experiment. Thorough mixing of dissimilar materials in

nugget zone was observed corresponding to best experimental conditions resulting in the

maximum tensile strength of 181 MPa.

Weizhang et al. [11] analyzed friction stir welding of 6061 Al to T2 pure Cu adopting tooth-

shaped joint configuration on microstructure and mechanical properties of joint. In this work

dissimilar 6061aluminum alloy and commercial pure copper were friction stir butt welded

adopting tooth-shaped joint configuration to investigate the influence of Al/Cu content in

welding bead (WB) on the microstructure and mechanical properties of the joint. Macro and

microstructure of the cross section of the joints were characterized via optical microscopy

(OM) and Scanning Electron Microscopy (SEM). According to the tensile tests, the

maximum and minimum failure loads were 7.53KN and 5.56KN obtained.

V.C. Sinha et al. [12] evaluated microstructure and mechanical properties of dissimilar joints

of aluminum alloy and pure copper by (Friction stir welding) FSW at variable tool rotational

speeds from 150 to 900 rpm in steps of 150 rpm at 60 mm/min travel speed and constant tilt

angle 2°.The interfacial microstructures of the joints were characterized by optical and

scanning electron microscopy. The grain size of stir zone and heat affected zone for all the

joints increased with the increase in tool rotational speeds. The Al4Cu9, AlCu, Al2Cu and

Al2Cu3 intermetallic phases have been observed at the interface and stir zone region of

dissimilar Al/Cu joints. Thus the welded joint when processed at 600rpm tool rotational

speed achieved maximum ultimate tensile strength of ~77% of aluminum.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org194

Page 5: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

M. Felix Xavier Muthu et al. [13] evaluated the material flow behavior of friction stir welding of AA1100 and pure copper under three pin profile whorl pin profile, plain taper pin profile

and taper treaded pin profile. Optical microscope, scanning electron microscope, X-ray

diffraction and EDS analysis were used to characterize the microstructural features. From

three pin profiles, the joints fabricated using plain taper pin profile result in better mechanical properties, with PTP result in yield strength of 101 MPa, tensile strength of 116 MPa and

joint efficiency of 68%.

Qiu-zheng ZHANG et al. [14] conducted dissimilar friction stir welding between 1060

aluminum alloy and annealed pure copper sheet with a thickness of 3 mm. It was observed

that pure copper and 1060 aluminum alloy were joined successfully by FSW at a rotation

rate of 1050 r/min and a welding speed of 30 mm/min with a configuration where copper is

located on advancing side, and most of the tool pin is inserted on the aluminum side. The

ultimate tensile strength of the joints is 148 MPa, failing across Cu/WN interface with a

brittle-ductile mixed fracture mode.

B. FSW tool pin positioning

The position of tool pin or probe is the most influencing and significant parameter that

governs the material flow and affects the weld quality for dissimilar Al to Cu FSW and it can

be divided into two parts:

(I) Tool pin offset: - The FSW tool movement from the center of the weld joint line towards

one of the two base plates is known as tool pin offset. No pin offset means the tool

centerline is exactly at the center of weld line between the two materials. The materials

such as aluminum and copper are very different from one another in conditions of physical

and mechanical characteristics like melting point and strength. So in such conditions of

material during FSW shifting the tool towards Al side is suggested as Cu having the

higher thermal expansion coefficient could not take away the larger amount of heat.

Provision of tool pin offset towards softer material side controls the formation of fragment

in the stir zone and promotes good stirring [15]. It is generally reported that the pin offset

towards the softer materials resulted in defect free joints [16, 17, 18, 19, 20].The optimum

value of tool offset depends upon the base material composition, thickness,

tool design and process parameters [22, 23−26]. The usage of 1.5−2 mm tool pin offset

was recommended in FSW of Al−Cu to attain good quality welding.

(II) Tool tilt angle: - The relative angular displacement of tool adjusted with reference to the

workpiece surface is known as the tool tilt angle. The position of tool when it is

perpendicular to the work surface then it is said to be zero tilt angle [27]. The tilt

angle of FSW tool contributes a major role with respect to weld joint quality [28-30]. It is

found that the bigger tilt angle gives a tight weld joint [30] and avoids the distribution

of work material on the top surface. It was reported that in FSW experimental work

between AA 2024 and pure copper with a 2° tilt angle of tool gives high strength as

compared to 0° because increase of tilt angle from 0° to 2° serve a free flow of particles

of Copper in aluminum matrix[24]. In one more research work of dissimilar FSW

between AA6061−T651 and Cu [27], tool tilt angle ranging from 2° to 4° was suggested.

As a result, it is important to recognize the optimum tool tilt angle for FSW of Al and Cu.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org195

Page 6: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

(III) FSW tool design features: - FSW tool is known as the heart of the welding process and

its main work is to provide appropriate heat and soft the workpiece materials by stirring

action at the interface of two workpiece. The FSW tool design consists of a shoulder and

a pin in which the shoulder generates the maximum heat input that is upto 80% riding

above the plate surface creating friction on the top portion of the plate and the pin which

is fully inserted inside the work piece at its interface. The main features of the

shoulder and pin are their diameters, surface profile, geometry and type of

surface [31].

Tool Shoulder: - The tool shoulder diameter is the vital part of the tool as it is

responsible for major heat generation and defect free welding which should be selected

carefully for dissimilar Al to Cu FSW. In dissimilar FSW of Al−Cu, microstructure

and mechanical properties, material deformation, IMCs development and plunge load

variation are affected by the type of tool used. Heat formation and resulting peak

temperature rising are mostly influenced by shoulder diameter and geometry

during FSW [32, 33].

Kush P. Mehta and Vishvesh J. Badheka [34] investigated and analyzed nine

different tool designs for dissimilar friction stir welding between aluminum and copper, while the rest of the process parameters were kept constant. Mechanical and

metallurgical tests such as macrostructure, microstructure, tensile test, hardness,

scanning electron microscope and electron X-ray spectrographs were performed to

assess the properties of dissimilar joints. The results exhibited that, the maximum joint

strength was achieved by the tool of cylindrical pin profile having 8 mm pin diameter.

Maximum hardness of HV 283 was obtained at weld made by the polygonal square pin

profile. It is found that small shoulder diameter along with large pin offset results in

continuous cavity defect (tunnel) and the combination of small shoulder diameter with

high welding speed results in a surface crack defect [35].

Tool shoulder design is the main aspect during FSW. Shoulder surface can be flat or

conical. Flat, convex and concave are the most important types of usually used shoulder

end surface profile. The ending surface of the shoulder might consist a variety of features

like grooves, scrolls, ridges, knurling and concentric circles to assist better mixing of

material [36, 37]. The shape of tool shoulder and its geometry have considerable effect

on the material flow system, weld bead shape and size, mechanical properties and

microstructure and on the development of IMCs for the dissimilar aluminum and copper

FSW. The choice of optimum feature of the shoulder is decided by the

work thickness and work piece and tool materials. Owing to few research articles,

designing of good and suitable shoulder features in dissimilar FSW of Al and Cu is still a

wide area of research.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org196

Page 7: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

Fig 4. Different types of shoulder shapes and surface features [38]

Tool pin: - The tool pin is the extended part of the tool shoulder with diameter less than

the tool shoulder diameter and the pin is main part of the tool that stirs and causes the

movement of material from advancing side to retreating side. The progress of tool pin

in the work piece causes shearing the material in front of tool and forces it behind the

tool. The main function of the revolving tool pin is to cause shearing the material in

front, giving stirring action to the deformed material and to move this stirred material

at the back of the tool for consolidating the joint. The geometry of the pin profile

governs the feed rate or welding speed of tool and is the main factor affecting

mechanical properties and microstructure [34].The most required design criteria features

of tool pin for dissimilar FSW of Al and Cu are pin length, pin diameter and surface

profile of pin. It is necessary during friction stir welding process to have appropriate and

sufficient contact of the tool shoulder with base work plates by proper axial plunge load

which is maintained by always keeping pin length 0.2-0.3 mm less compared to

workpiece thickness [1].

M. Felix Xavier Muthu et al. [13] studied material flow behavior of friction stir welding

of AA1100 and pure copper under three pin profile whorl pin profile, plain taper pin

profile and taper treaded pin profile and its effect on microstructure, microhardness and

tensile properties were analyzed. Optical microscope, scanning electron microscope, X-

ray diffraction and EDS analysis were used to characterize the microstructure features.

Among the three pin profiles, plain taper pin profile results in defect-free stir zone and

maximum joint properties of yield strength of 101 MPa, tensile strength of 116 MPa and

joint efficiency of 68% compared with the other pin profiles. However, the microhardness

plots are more or less identical for all the pin profiles but follows fluctuating trend.

The different types of pin shapes and profile are shown in fig 5.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org197

Page 8: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

Fig 5. Different types of pin shapes and profile [39]

The diameter of the shoulder and the pin diameter share a relation with each other known

as Shoulder diameter to pin diameter ratio (SPR). SPR value depends on type of alloy of

aluminium and work piece thickness. SPR is comparatively high for dissimilar welding

compared to with similar welding. The high SPR taken throughout FSW of Al−Cu

increases the heat generated and this bigger heat can be efficiently distributed by

controlling other process parameters, i.e., arrangement of workpieces, tool pin offset,

traverse speed and rotational speed. In dissimilar friction stir welding of larger work

piece thickness higher SPR is required.

C. Mechanical characterization and microstructure

Many of researchers concentrated on mechanical properties such as tensile strength, hardness

and bending strength of friction stir welded specimens to form a good quality welded joint

that can be given practical application such as electrical and thermal applications. Also

microstructure of friction stir welded joint was studied to see formation of aluminium and

copper intermetallic compound formation as well as Al Cu phases in weld nugget zone so that

researchers can get idea of formation of microstructure for dissimilar aluminium to copper

friction stir welding.

Radmir Rzaev et al. [40] studied friction stir welding of dissimilar joints of copper M1, M3

and aluminum AD1 (AMg6) alloys of 3 mm thickness. The microstructure, mechanical

properties and phase components of welded joints obtained by FSW were studied using

various methods of metal physical analysis including X-ray diffraction, mechanical tests for

tearing and bending. Copper (M1) and aluminum alloy (AD1) of butt joints are welded by

FSW with the following parameters of the mode: speed of rotation of 900 rpm, welding speed

25 mm/min, tool angle of 3 degrees, copper is located on the advancing side, and most of the

tool pin offset on the copper part. The average hardness values in the WN are higher than for

the being welded metals, probably because of the high density of dislocations and the

accumulation of grain boundaries formed during the lifetime of the regime SPD upon contact

with the tool pin.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org198

Page 9: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

Prakash Kumar Sahu et al. [41] conducted dissimilar friction stir welding between aluminium

1050 alloy and pure copper plates by varying different process parameters such as rotational

speed of 600rpm to 2400rpm in interval of 600 rpm, feed rate ranging from 20 to 40 mm/min

and tool offset ranging from 0.5 to 2mm towards aluminium side. Mechanical Properties and

Microstructures of dissimilar Al/Cu friction Stir welding Joints were investigated and it was

found that defect free joint can be obtained, when the hard Cu plate is placed on the

advancing side while large volume defects are observed when Al plates is placed on the

advancing side. Also pin offset of not less than 1.5 mm towards soft Al matrix leads to defect

free joint and good metallurgical bonding between the Al and Cu. At smaller pin offset, the

defects arise due to high Cu percentage in the welded zone. At tool rotation rate of 1200

rev/min, welding speed of 30 mm/min, 0.1 mm plunging depth and 1.5 mm offset towards Al

alloy yield highest ultimate tensile strength of 126.0 MPa and yield strength of 119.3 MPa

which constitute 95% and 100%, respectively, of the 1050 Al base metal was obtained. SEM

morphologies of the fracture surfaces indicate that the type of fracture was not purely ductile

which leads less tensile strength. The XRD analysis indicates the presences of the various

IMCs and the line scan indicates the mixed flow of Al/Cu material

M. Felix Xavier Muthu et al. [42] studied tool travel speed effects on the mechanical

properties and microstructure of friction stir welded aluminum–copper joints. In this research

work conducted 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, intermetallic 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 and the joint fabricated at tool travel speed of

80 mm/min results in higher tensile strength and joint efficiency of 113 MPa and 70.62%

respectively. The optimal heat contribution is low enough to decrease the diffusion between

Al–Cu interfaces, which outcome in the thin intermetallic thickness of 1.9µm. The nano

scaled thin continuous intermetallics of Al2Cu, AlCu and Al4Cu9 give high tensile strength.

H. Barekatain et al. [43] conducted friction stir welding of Severely Plastic deformed

Aluminum AA 1050 and Commercially Pure Copper Sheets. 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. AA 1050 aluminum alloy and commercially pure

copper has been joined successfully by FSW in annealed and CGPed conditions. Several

forms of intermetallic compounds are found in weld zone of FSWed annealed and CGPed

samples. These compounds mainly consist of Al2Cu and Al4Cu9. In tensile test results,

generally the weakest part of weld joints of annealed and CGPed samples are Al base metal

and stir zone, respectively.

LI Xia-wei et al. [44] conducted the dissimilar friction stir welding of pure copper/1350

aluminum alloy sheet with a thickness of 3 mm and mechanical properties and microstructure

of formed weld nugget were analyzed Most of the rotating pin was inserted into the

aluminum alloy side through a pin-off technique. Sound welds were obtained at a rotation

speed of 1000 r/min and a welding speed of 80 mm/min. The hardness at the copper side of

the nugget is higher than that at the aluminum side. The hardness at the bottom of the nugget

is generally higher than other regions. The UTS and elongation of the dissimilar joints are

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org199

Page 10: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

152 MPa and 6.3%, respectively, and the dissimilar joints fail in a ductile-brittle mixed

fracture mode. Also no intermetallic compound is found according to the XRD results.

Complex vortex-like and swirl patterns are formed in the dissimilar FSW joint. The lamella

structure in the bottom of the nugget is more homogeneous and finer than other regions.

P. Xue et al. [45] carried out the work on friction stir welding of butt joints of 1060 aluminum

alloy and commercially pure copper and the effect of welding parameters on surface

morphology, interface microstructure and mechanical properties was investigated. It was

concluded that sound defect-free joint could be obtained only when the hard Cu plate was

fixed at the advancing side. A large volume defect was observed when the soft Al plate was

fixed at the advancing side. Sound defect-free joints were obtained under the larger pin

Offsets of not less than 2mm to the Al matrix, and a good metallurgical bonding between the

Cu bulk/pieces and Al matrix was achieved. Sufficient reaction were achieved in the FSW

Al–Cu joints produced at higher rotation rates between 800 and 1000 rpm and proper pin

offsets of 2 and 2.5mm, resulting in the good tensile properties. The joints produced at

600rpm under a pin offset of 2mm showed sound bending properties.

III. CONCLUSIONS AND FUTURE WORK:-

The welding of aluminum and copper by friction stir welding has been briefly reviewed in form

of various aspects such as optimization of different process parameters such as rotational speed,

welding speed, different tool design and geometry aspects, FSW tool pin positioning such as

tool pin offset and tool tilt angle, and its effects on mechanical properties such as tensile

strength, hardness of welded joint and also microstructure study of the

formed weld nugget to open a research window to researchers with a view to expand the

welding process to other aluminum and copper alloys with the view of achieving optimized

welding parameters. Research on friction stir welding of aluminum alloy to copper has

still not been comprehensively researched. Also adding, there is a need of comprehensive

information of tool design criteria and tool material for various thicknesses and alloys of this

welding process. But there is still, a strong requirement in increasing the industrial applications

of friction stir welding between aluminum alloy and copper in the manufacturing area.

Thus, the applications of the friction stir welding method to weld aluminium alloy and copper

alloys and various material shapes is of significance in the growth of their industrial

applications. In above review, the friction stir welding of dissimilar materials

concentrating on aluminium alloys and copper has been successfully carried out. It will

present complete overview for the current and also offer the current state of research on

friction stir welding between aluminium alloys and copper to fill the gaps with new

research ideas.

Also, the novel and different tool design such as the double shoulder bobbin tool design

having two shoulders one riding on the upper side of the plates to be welded and another on

lower side with a pin in between the two shoulders which is fully within the work plates to be

welded has still not yet been worked in past for dissimilar materials. The double sided friction

stir welding using a bobbin tool design has been employed for similar materials in FSW

especially for similar aluminium alloys. Improvisation in mechanical properties of welded joint

and microstructure formation can be worked out with the help of double shoulder bobbin tool

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org200

Page 11: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

which has the benefit of generating a processed region in the workpiece having

rectangular cross section, as opposite to the triangular zone which is most probably

established when conventional friction stir welding tool designs are used. Also, the total axial

force on the work piece is approximately zero, which has major useful implications in machine

design and cost.

References

[1]MISHRA R S, MA Z. Friction stir welding and processing [J].Materials Science and

Engineering R: Reports, 2005, 50(1): 1−78. [2]Aleem Pasha M.D, Ravinder Reddy P, Laxminarayana P & Ishtiaq Ahmad Khan, “INFLUENCE OF PROCESS AND TOOL PARAMETERS ON FRICTION STIR WELDING – OVER VIEW”, International Journal of Applied Engineering and Technology, 2014 Vol. 4 (3),September, pp.54-69. [3]S. Rajakumar & V. Balasubramanian, “Establishing relationships between mechanical properties of aluminium alloys and optimized friction stir welding process parameters. Materials and Design 40 (2012) 17–35.

[4] XUE P, NI D, WANG D, XIAO B, MA Z. Effect of friction stir welding parameters on the

microstructure and mechanical properties of the dissimilar Al−Cu joints [J]. Materials Science

and Engineering A, 2011, 528(13): 4683−4689.

[5] FIROUZDOR V, KOU S. Al-to-Cu friction stir lap welding [J].Metallurgical and Materials Transactions A, 2012, 43(1): 303−315. [6] BABU A S, DEVANATHAN C. Overviews of friction stir welding [J]. International Journal of Research in Mechanical Engineering and Technology, 2013, 3(2): 259−265. [7] GALVAO I, LOUREIRO A, VERDERA D, GESTO D,RODRIGUES D. Influence of tool offsetting on the structure and morphology of dissimilar aluminum to copper friction-stir welds [J]. Metallurgical and Materials Transactions A, 2012, 43(13):5096−5105. [8] AKINLABI E T, ELS-BOTES A, LOMBARD H. Effect of tool displacement on defect formation in friction stir welding of aluminium and copper [C]//Proceedings of the 8th International Friction Stir Welding Symposium. Hamburg, Germany, TWI Ltd, 2010: 216−224. [9] Sachindra Shankar & Somnath Chattopadhyaya, “Friction stir welding of commercially pure copper and 1050 aluminum alloys”, Materials today proceedings August 2019. [10] Nitish kumar, Gaurav dhuria & Rajbir Singh “Evaluation of Tensile Strength in Friction Stir Welded Aluminum alloy 6101-T6 and commercially pure Copper joints”. Materials Today: Proceedings 5 (2018) 19230–19236. [11] Weizhang, Yifu shen & Yinfei yan, “Dissimilar friction stir welding of 6061 Al to T2 pure Cu adopting tooth-shaped joint configuration on microstructure and mechanical properties”, Materials science & Engg April 2017. [12] V.C. Sinha S. Kundu and S. Chatterjee, “Microstructure and Mechanical Properties of Similar and Dissimilar Joints of Aluminium Alloy and Pure Copper by Friction Stir Welding”, Elsevier September 2016. [13] M. FELIX XAVIER MUTHU & V. JAYABALAN “Effect of pin profile and process parameters on microstructure and mechanical properties of friction stir welded Al−Cu joints Transactions of Nonferrous Metals Society of China 26(4):984-993 · April 2016.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org201

Page 12: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

[14] Qiu-zheng ZHANG, Wen-biao GONG & Wei LIU ,“Microstructure and mechanical properties of dissimilar Al−Cu joints by friction stir welding”, Elsevier June 2015, Trans. Nonferrous Met. Soc. China 25(2015) 1779−1786. [15] ESMAEILI A, BESHARATI G M, ZAREIE R H. Experimental investigation of material flow and welding defects in friction stir welding of aluminum to brass [J]. Materials and Manufacturing Processes, 2012, 27(12): 1402−1408.

[16] LEE W B, JUNG S B. Void free friction stir weld zone of the dissimilar 6061 aluminum and

copper joint by shifting the tool insertion location [J]. Materials Research Innovations, 2004,

8(2): 93−96.

[17] OUYANG J, YARRAPAREDDY E, KOVACEVIC R. Microstructural evolution in the friction

stir welded 6061 aluminum alloy (T6-temper condition) to copper [J]. Journal of Materials

Processing Technology, 2006, 172(1): 110−122.

[18] SINGH S H, MAHMEEN M. Effect of tool pin offset on the mechanical properties of dissimilar

materials based on friction stir welding (FSW) [J]. International Journal of Modern Trends in

Engineering and Research, 2016, 3: 75−80.

[19] FOTOUHI Y, RASAEE S, ASKARI A, BISADI H. Effect of transverse speed of the tool on

microstructure and mechanical properties in dissimilar butt friction stir welding of Al5083–

copper sheets [J]. Engineering Solid Mechanics, 2014, 2(3): 239−246

[20] GIHAD K, MERAH N, SHUAIB A, BADOUR F, BAZOUNE A. Experimental and numerical

investigations of friction stir welding of aluminum to copper [M]//Applied Mechanics, Behavior

of Materials, and Engineering Systems. Springer International Publishing, 2017:129−138.

[21] BARCELLONA A, BUFFA G, FRATINI L. Process parameters analysis in friction stir welding of AA6082-T6 sheets[C]//Proceeding of Esaform Conference on Material Forming 2004.Trondheim, Norway, 2004: 371−374. [22] AGARWAL S P, NAGESWARAN P, ARIVAZHAGAN N,RAMKUMAR K D. Development of friction stir welded butt joints of AA 6063 aluminium alloy and pure copper [C]//International Conference on Advanced Research in Mechanical Engineering. Uttarakhand, India: IPM rt. Ltd Naintal, 2012: 46−50 [23] XUE P, NI D, WANG D, XIAO B, MA Z. Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al−Cu joints [J]. Materials Science and Engineering A, 2011, 528(13): 4683−4689. [24] TOLEPHIH M H, MAHMOOD H M, HASHEM A H, ABDULLAH E T. Effect of tool offset and tilt angle on weld strength of butt joint friction stir welded specimens of AA2024 aluminum alloy welded to commercial pure cupper [J]. Chemistry and Materials Research A, 2013, 3(4): 49−58 [25] OUYANG J, YARRAPAREDDY E, KOVACEVIC R.Microstructural evolution in the friction stir welded 6061 aluminum alloy (T6-temper condition) to copper [J]. Journal of Materials Processing Technology, 2006, 172(1): 110−122. [26] SHOJAEEFARD M H, KHALKHALI A, AKBARI M, TAHANI M. Application of Taguchi optimization technique in determining aluminum to brass friction stir welding parameters [J]. Materials & Design, 2013, 52: 587−592. [27] AKBARI M, ABDI BEHNAGH R, DADVAND A. Effect of materials position on friction stir lap welding of Al to Cu [J]. Science and Technology of Welding and Joining, 2012, 17(7): 581−588 [28] ARICI A, SELALE S. Effects of tool tilt angle on tensile strength and fracture locations of friction stir welding of polyethylene [J].Science and Technology of Welding and Joining, 2007, 12(6): 536−539. [29] BOZKURT Y, KENTLI A, UZUN H, SALMAN S. Experimental investigation and prediction of mechanical properties of friction stir welded aluminium metal matrix composite plates [J]. Materials Science, 2012, 18(4): 336−340.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org202

Page 13: A Brief Review of Friction Stir Welding Between Dissimilar ...joics.org/gallery/ics-2900.pdf · A Brief Review of Friction Stir Welding Between Dissimilar Aluminium Alloy and Pure

[30] MEHTA K P, BADHEKA V. Effects of tilt angle on the properties of dissimilar friction stir welding copper to aluminum [J]. Materials and Manufacturing Processes, 2016, 31(3): 255−263. [31] RAI R, DE A, BHADESHIA H, DEBROY T. Review: Friction stir welding tools [J]. Science and Technology of Welding and Joining, 2011, 16(4): 325−342. [32] BABU A S, DEVANATHAN C. An overview of friction stir welding [J]. International Journal of Research in Mechanical Engineering and Technology, 2013, 3(2): 259−265.

[33] SINGH S H, MAHMEEN M. Effect of tool pin offset on the mechanical properties of dissimilar materials based on friction stir welding (FSW) [J]. International Journal of Modern Trends in

Engineering and Research, 2016, 3: 75−80. [34] Kush P. MEHTA & Vishvesh J. BADHEKA “Influence of tool pin design on properties of dissimilar copper to aluminum friction stir welding” Elsevier Volume 27, Issue 1, January 2017, Pages 36-54. [35] MEHTA, KUSH P, BADHEKA V. Experimental investigation of process parameters on defects generation in copper to AA6061-T651 friction stir welding [J]. International Journal of Advances in Mechanical and Automobile Engineering, 2016, 3: 55−58 [36] MISHRA R S, MA Z. Friction stir welding and processing [J]. Materials Science and Engineering R: Reports, 2005, 50(1): 1−78 [37] ZHANG Y, CAO X, LAROSE S, WANJARA P. Review of tools for friction stir welding and processing [J]. Canadian Metallurgical Quarterly, 2012, 51(3): 250−261. [38] Y.N. Zhang, X. Cao, S. Larose, P. Wanjara, Can. Metall. Q. 51 (3) (2012) 250–261. [39]Nidhi SHARMA, Zahid A. KHAN, Arshad Noor SIDDIQUEE.Friction stir welding of

aluminum to copper—An overview, Trans. Nonferrous Met. Soc. China 27(2017) 2113−2136

[40]Radmir Rzaev, Alexander Chularis,Vladimir Smirnov & Larisa Semyenova, “The Influence of the Friction Stir Welding Parameters on the Formation of Welded Joint of Aluminum and Copper Alloys”, Materials Today Proceedings 11 (2019), 534–542 [41] Prakash Kumar Sahu, Sukhomay Pal, Surjya K. Pal & Rahul Jain, “Influence of Plate Position, Tool Offset and Tool Rotational Speed on Mechanical Properties and Microstructures of Dissimilar Al/Cu Friction Stir Welding Joints”, Journal of Materials Processing Technology, April 2016. [42] M. Felix Xavier Muthu & V. Jayabalan, “Tool travel speed effects on the microstructure of friction stir welded aluminum–copper joints”, Journal of Materials Processing Technology March 2015.

[43] H. Barekatain & M. Kazeminezhad, “Microstructure and Mechanical Properties in dissimilar

Butt Friction Stir Welding of Severely Plastic Deformed Aluminum AA 1050 and commercially

pure Copper Sheets”, Journal of material science & Engg, Feb 2014.

[44] LI Xia-wei, ZHANG Da-tong, QIU Cheng & ZHANG Wen, “Microstructure and mechanical

properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding”,

Trans. Nonferrous Met. Soc. China 22(2012) 1298_1306

[45] P. Xue, D.R. Ni, D. Wang, B.L. Xiao & Z.Y. Ma, “Effect of friction stir welding parameters on

the microstructure and mechanical properties of the dissimilar Al–Cu joints”, Materials Science

and Engineering A 528 (2011) 4683–4689.

Journal of Information and Computational Science

Volume 10 Issue 4 - 2020

ISSN: 1548-7741

www.joics.org203


Related Documents