Journal articles: 'Aluminium - copper welds'

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Leal, Rui M., Carlos Leitão, Altino Loureiro, and Dulce M. Rodrigues. "Imaging characterization of friction stir welds in the AA 5182-H111 aluminium alloy." Microscopy and Microanalysis 15, S3 (July 2009): 81–82. http://dx.doi.org/10.1017/s1431927609990869.

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AbstractThe environmentally friendly friction stir welding (FSW) process is being increasingly used in joining similar and dissimilar aluminium and copper alloys and other soft materials. In this process a rotating tool promotes significant shear strain and frictional heating of the base materials, in order to stir them into a highly plasticized weld region, at the trailing side of the tool. Due to the intense plastic deformation, complex material flow patterns, such as vortices, swirls and whorls occur during welding. In dissimilar welds, these patterns are readily revealed by differential etching and the respective microstructures characterized. However, in similar welds, such as the welds between plates of AA 5182-H111 aluminium alloy, it is hard to distinguish the different features in the welds and characterize their microstructures. Fig. 1 illustrates optical and TEM micrographs of a weld in this alloy. In the optical image of the weld, at the top of the image, it is possible to distinguish three main areas signalized by numbers: the weld nugget (1), with a very fine grain structure with 2.8 um mean grain size, and a transition region (2) between the nugget and the base material (3), which is usually called the Thermomechanical Affected Zone (TMAZ).

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Galvão, Ivan, Carlos Leitão, Altino Loureiro, and Dulce Rodrigues. "Friction Stir Welding of very thin plates." Soldagem & Inspeção 17, no. 1 (March 2012): 02–10. http://dx.doi.org/10.1590/s0104-92242012000100002.

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The results obtained in present research, relative to friction stir welding of 1 mm thick plates of aluminium, copper, copper-zinc and zinc alloys, prove that the application of the process in the joining of very thin plates is feasible and desirable. In fact, independently of the base material, the welds produced presented very good morphological characteristics and significant grain refinement in the nugget. Tensile and hardness tests proved that all the welds were at least in even-match relative to the base material properties. Based on the AA 5182 aluminium alloy results it was also possible to conclude that augmenting the welding speed, which improves process productivity, increases grain refinement in the nugget, improving the mechanical properties of the welds.

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Titilayo, Akinlabi Esther, Madyira Daniel Makundwaneyi, and Akinlabi Stephen Akinwale. "Reconfiguration of a Milling Machine to Achieve Friction Stir Welds." Applied Mechanics and Materials 232 (November 2012): 86–91. http://dx.doi.org/10.4028/www.scientific.net/amm.232.86.

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This paper reports on the reconfiguration of a milling machine to produce friction stir welds of aluminium and copper and friction stir processing of 6086 aluminium alloy. Friction stir welding tools were designed and manufactured from tool steel. The tools were inserted into the chuck of the milling machine. A backing plate was also specially designed and manufacturedfrom mild steel to protect the milling machine table and was placed on the bed with the use of T-nuts. The plates were secured firmly on the backing plate with the use of specially designed clamping fixtures. The varied welding speeds and the rotational speeds were achieved using the control system on the vertical milling machine. The reconfigured milling machine was successfully employed to produce friction stir processing of aluminium and friction stir welds of aluminium and copper. An optimum joint strength of 74% was achieved.

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Carvalho, G. H. S. F. L., I. Galvão, R. Mendes, R. M. Leal, and A. Loureiro. "Influence of base material properties on copper and aluminium–copper explosive welds." Science and Technology of Welding and Joining 23, no. 6 (December 27, 2017): 501–7. http://dx.doi.org/10.1080/13621718.2017.1417783.

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Marya, M., and S. Marya. "Interfacial microstructures and temperatures in aluminium–copper electromagnetic pulse welds." Science and Technology of Welding and Joining 9, no. 6 (December 15, 2004): 541–47. http://dx.doi.org/10.1179/174329304x8685.

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Singh, Prem, Dharmpal Deepak, and Gurinder Singh Brar. "Friction Crush Welding of Similar Metals: An Overview." Asian Journal of Engineering and Applied Technology 7, no. 2 (October 5, 2018): 48–51. http://dx.doi.org/10.51983/ajeat-2018.7.2.957.

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Friction Crush Welding (FCW) is a newly developed technique which can be used for welding of similar materials with or without filler metal. In this process, welding between two work pieces occurs due to relative motion between work pieces and rotating cylindrical tool, which causes crushing of material to produce weld. Similar weld which include welds of aluminium, steel and copper and their alloy have been successfully produced by few researchers. This review covers the work conducted in the field of FCW and throws light on the future use of FCW for welding similar and dissimilar materials.

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Silva, Rafael Gomes Nunes, Sylvia De Meester, Koen Faes, and Wim De Waele. "Development and Evaluation of the Ultrasonic Welding Process for Copper-Aluminium Dissimilar Welding." Journal of Manufacturing and Materials Processing 6, no. 1 (January 1, 2022): 6. http://dx.doi.org/10.3390/jmmp6010006.

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The demand for joining dissimilar metals has exponentially increased due to the global concerns about climate change, especially for electric vehicles in the automotive industry. Ultrasonic welding (USW) surges as a very promising technique to join dissimilar metals, providing strength and electric conductivity, in addition to avoid metallurgical defects, such as the formation of intermetallic compounds, brittle phases and porosities. However, USW is a very sensitive process, which depends on many parameters. This work evaluates the impact of the process parameters on the quality of ultrasonic spot welds between copper and aluminium plates. The weld quality is assessed based on the tensile strength of the joints and metallographic examination of the weld cross-sections. Furthermore, the welding energy is examined for the different welding conditions. This is done to evaluate the influence of each parameter on the heat input resulting from friction at the weld interface and on the weld quality. From the obtained results, it was possible to optimise parameters to achieve satisfactory weld quality in 1.0 mm thick Al–Cu plate joints in terms of mechanical and metallurgical properties.

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Demonie, Wim, Koen Faes, and Wim De Waele. "Influence of process parameters on the weld quality of dissimilar Cu-Al magnetic pulse welded sheets." International Journal Sustainable Construction & Design 7, no. 1 (October 21, 2016): 8. http://dx.doi.org/10.21825/scad.v7i1.3637.

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Little is known about the influence of the main geometrical parameters (overlap, stand-off and free length) and the energy input on welds formed by electromagnetic pulse welding. The Taguchi experimental design method was applied for determining the underlying relations for dissimilar sheet welding of copper and aluminium. The weld quality was evaluated based on four output parameters: the weld length, the size of the interfacial layer, the lap shear strength and the thickness reduction of the flyer sheet. The influence of the overlap and free length showed to be non-negligible; this in contrast to the small amount of attention these parameters receive in other publications.

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Avettand-Fènoël, Marie Noëlle, Roland Taillard, Christophe Herbelot, and Abdellatif Imad. "Structure and Mechanical Properties of Friction Stirred Beads of 6082-T6 Al Alloy and Pure Copper." Materials Science Forum 638-642 (January 2010): 1209–14. http://dx.doi.org/10.4028/www.scientific.net/msf.638-642.1209.

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Friction stir welding (FSW) is a quite recent welding method which takes advantage of being performed in the solid state. Compared with the usual welding processes, it therefore presents many benefits such as a lower heat-input, a reduction of residual stresses and an elimination of the solidification defects etc.. Up to now, it has essentially been applied to aluminium alloys and far more recently to a small number of bimaterials. The present study deals with three kinds of beads between pure copper and a 6082 aluminium alloy. Both materials were butt joined by FSW. The welds differ by the location of the tool which was placed either at the interface between the two metals or on the copper or the 6082 side of this surface. Their structure was characterized at a multi-scale level by using a number of techniques. Tensile and microhardness tests were also performed. The tool place is shown to govern the microstructure and the ensuing mechanical behaviour of the weld. Its influence on the plastic flow with its repercussions on i) welding defects and ii) mechanical properties is going to be demonstrated. Some ways of improvement of the welding process will finally be suggested.

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Demirorer, Mete, Wojciech Suder, Supriyo Ganguly, Simon Hogg, and Hassam Naeem. "Development of laser welding of high strength aluminium alloy 2024-T4 with controlled thermal cycle." MATEC Web of Conferences 326 (2020): 08005. http://dx.doi.org/10.1051/matecconf/202032608005.

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An innovative process design, to avoid thermal degradation during autogenous fusion welding of high strength AA 2024-T4 alloy, based on laser beam welding, is being developed. A series of instrumented laser welds in 2 mm thick AA 2024-T4 alloys were made with different processing conditions resulting in different thermal profiles and cooling rates. The welds were examined under SEM, TEM and LOM, and subjected to micro-hardness examination. This allowed us to understand the influence of cooling rate, peak temperature, and thermal cycle on the growth of precipitates, and related degradation in the weld and heat affected area, evident as softening. Although laser beam welding allows significant reduction of heat input, and higher cooling rates, as compared to other high heat input welding processes, this was found insufficient to completely supress coarsening of precipitate in HAZ. To understand the required range of thermal cycles, additional dilatometry tests were carried out using the same base material to understand the time-temperature relationship of precipitate formation. The results were used to design a novel laser welding process with enhanced cooling, such as with copper backing bar and cryogenic cooling.

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Akinlabi, Esther Titilayo, and Stephen Akinlabi. "Effect of Shoulder Diameter on the Resulting Interfacial Regions of Friction Stir Welds between Aluminium and Copper." Advanced Materials Research 299-300 (July 2011): 1146–50. http://dx.doi.org/10.4028/www.scientific.net/amr.299-300.1146.

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This paper reports the effect of shoulder diameter on the resulting interfacial regions of joints between aluminium and copper produced by the friction stir welding process. The welds were produced using three shoulder diameter tools, viz; 15, 18 and 25 mm. This paper focuses on welds produced at a constant rotational speed of 600 rpm and feed rate of 50 mm/min varying the shoulder diameters. Analysis of the force feedback revealed that the advancing force, the downward vertical force and the torque increases as the shoulder diameter increases. Microstructural characterization was conducted on the joint interfaces and it was observed that the widths of the interfacial regions comprising of the Stir Zone and the Thermo – Mechanically Affected Zone (TMAZ) increases as the shoulder size increases.

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Alléhaux, Delphine, and François Marie. "Mechanical and Corrosion Behaviour of the 2139 Aluminium-Copper Alloy Welded by the Friction Stir Welding Using the Bobbin Tool Technique." Materials Science Forum 519-521 (July 2006): 1131–38. http://dx.doi.org/10.4028/www.scientific.net/msf.519-521.1131.

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The present study deals with the properties assessment of a new generation aluminium-copper alloy, developed by ALCAN and designed 2139, welded by the bobbin tool technique of the FSW process. Considering the best performances of this age formable alloy after T8 aging, both the T4 and T8 tempers prior to welding are assessed. Therefore, the behaviour under static and fatigue load conditions and also in damage tolerance including both fracture toughness and fatigue crack propagation of the FSW bobbin tool weld on 2139 after T8 post aging and on the T8 as welded condition are discussed. The corrosion resistance of the welds is investigated through an accelerated corrosion test with intent to evaluate the intergranular corrosion sensitivity of the weld and the impact of an artificial aging on the properties developed by the T8 as welded condition is also presented.

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Loureiro, A., R. Mendes, J. B. Ribeiro, R. M. Leal, and I. Galvão. "Effect of explosive mixture on quality of explosive welds of copper to aluminium." Materials & Design 95 (April 2016): 256–67. http://dx.doi.org/10.1016/j.matdes.2016.01.116.

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Mubiayi, Mukuna P., and Esther T. Akinlabi. "Characterization of the intermetallic compounds in aluminium and copper friction stir spot welds." Materials Today: Proceedings 4, no. 2 (2017): 533–40. http://dx.doi.org/10.1016/j.matpr.2017.01.054.

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15

Abima, Cynthia Samuel, Esther Titilayo Akinlabi, Stephen Akinwale Akinlabi, Olawale Samuel Fatoba, and Oluseyi Philip Oladijo. "Microstructural, mechanical and corrosion properties of aluminium MIG welds reinforced with copper powder." International Journal of Advanced Manufacturing Technology 105, no. 12 (November 18, 2019): 5181–90. http://dx.doi.org/10.1007/s00170-019-04546-9.

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16

Seshagiri, P. C., B. S. Nair, G. M. Reddy, K. S. Rao, S. S. Bhattacharya, and K. P. Rao. "Improvement of mechanical properties of aluminium–copper alloy (AA2219) GTA welds by Sc addition." Science and Technology of Welding and Joining 13, no. 2 (February 2008): 146–58. http://dx.doi.org/10.1179/174329308x283866.

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17

Carvalho, G. H. S. F. L., R. Mendes, R. M. Leal, I. Galvão, and A. Loureiro. "Effect of the flyer material on the interface phenomena in aluminium and copper explosive welds." Materials & Design 122 (May 2017): 172–83. http://dx.doi.org/10.1016/j.matdes.2017.02.087.

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18

Lynch, Stan. "Failures of metallic components involving environmental degradation and material- selection issues." Corrosion Reviews 35, no. 4-5 (October 26, 2017): 191–204. http://dx.doi.org/10.1515/corrrev-2017-0023.

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AbstractEnvironmentally assisted failures involving poor materials selection (or heat treatment), along with some examples where the specified material was (inadvertently) not used, are described. The materials discussed are martensitic steels, stainless steels, aluminium alloys, and copper alloys. The examples discussed include some cases where the material-selection issue was with welds, coatings, or insulation rather than the component material per se. The failure modes discussed are hydrogen embrittlement, stress-corrosion cracking, corrosion fatigue, metal-induced embrittlement, galvanic corrosion, selective corrosion (dealloying), and intergranular corrosion. The characteristics of fracture/corrosion, which contribute toward correctly diagnosing the modes and causes of failure, are also outlined along with comments on the mechanisms involved.

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T. Akinlabi, Esther, and Stephen A. Akinlabi. "Effect of Heat Input on the Properties of Dissimilar Friction Stir Welds of Aluminium and Copper." American Journal of Materials Science 2, no. 5 (December 1, 2012): 147–52. http://dx.doi.org/10.5923/j.materials.20120205.03.

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AKINLABI, Esther T., Anthony ANDREWS, and Stephen A. AKINLABI. "Effects of processing parameters on corrosion properties of dissimilar friction stir welds of aluminium and copper." Transactions of Nonferrous Metals Society of China 24, no. 5 (May 2014): 1323–30. http://dx.doi.org/10.1016/s1003-6326(14)63195-2.

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Roeygens, Lodewijk, Wim De Waele, and Koen Faes. "Experimental investigation of the weldability of tubular dissimilar materials using the electromagnetic welding process." International Journal Sustainable Construction & Design 8, no. 1 (October 30, 2017): 8. http://dx.doi.org/10.21825/scad.v8i1.6810.

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This paper describes the magnetic pulse welding process (MPW) for tubes. Material combinations of aluminium to steel and copper to aluminium were experimentally evaluated. The first major goal of this work is to experimentally obtain the optimal input parameters like the discharge energy, the stand-off distance and the tool overlap for MPW of the material combinations. Welding windows with all possible input parameters are created for both material combinations. Furthermore, a comparison is done between three coil systems; a single turn coil with field shaper, a single turn coil with a field shaper and transformer and a multi-turn coil and field shaper. Metallographic investigation of the samples, hardness tests and leak tests were executed to determine the most suitable machine set-up and the optimal input parameters for each set-up. A second major goal is to determine the influence of the target tube wall thickness on the deformation of tube-tube welds when no internal support is used.

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Mohanraj, N., N. Mathan Kumar, P. Prathap, P. Ganeshan, K. Raja, V. Mohanavel, Alagar Karthick, and M. Muhibbullah. "Mechanical Properties and Electrical Resistivity of the Friction Stir Spot-Welded Dissimilar Al–Cu Joints." International Journal of Polymer Science 2022 (June 3, 2022): 1–7. http://dx.doi.org/10.1155/2022/4130440.

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Alternative methods for dissimilar metal joining particularly aluminium and copper have gain interest in manufacturing sectors. Friction stir spot welding was carried out on the AA6061 and C11000 wires of 2 mm diameter. This research paper reported the results on microstructures and mechanical properties of the spot-welded joints, and also special attention is provided for electrical resistivity of the welds. The microstructures reveal the information of grain structure and bonding. The width of diffusion layer significantly reduced with low dwell times. For a plunge depth of 1 mm, the maximum tensile strength (294 MPa) is achieved during the higher rotational speed (1400 rpm). For the same plunge depth, lower tensile strength values are exhibited by the joint produced using the lower rotational speed (800 rpm). Hardness of the weld region recorded 70 HV which is less than Cu (115 HV) and greater than Al (40 HV). FSSW joints (0.30 to 0.34 μΩ) offered higher range of electrical resistivity than that of base metal (0.02 μΩ). The results highlighted in this paper might be helpful for both academic researchers and industrialists.

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Rao, K. Srinivasa, G. Madhusudan Reddy, and K. Prasad Rao. "Studies on partially melted zone in aluminium–copper alloy welds—effect of techniques and prior thermal temper." Materials Science and Engineering: A 403, no. 1-2 (August 2005): 69–76. http://dx.doi.org/10.1016/j.msea.2005.04.041.

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Andrade, D. G., I. Galvão, D. Verdera, C. Leitão, and D. M. Rodrigues. "Influence of the structure and phase composition of the bond interface on aluminium–copper lap welds strength." Science and Technology of Welding and Joining 23, no. 2 (May 22, 2017): 105–13. http://dx.doi.org/10.1080/13621718.2017.1329078.

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Kolnes, Mart, Jakob Kübarsepp, Fjodor Sergejev, Märt Kolnes, Marek Tarraste, and Mart Viljus. "Wear Behavior of Ceramic-Metal Composites as Tool Material for FSW of Copper." Solid State Phenomena 320 (June 30, 2021): 144–49. http://dx.doi.org/10.4028/www.scientific.net/ssp.320.144.

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Friction stir welding (FSW) is employed primarily for metals characterized by poor weldability at fusion welding: aluminium, magnesium, titanium and copper alloys as well as stainless steels. The focus of the study was on the feasibility of application of WC-based hardmetal 85WC-Co and TiC-based cermet 80TiC-NiMo as potential tool materials for FSW of copper. The single-pass welding trials of Cu sheets were performed using a vertical milling machine. For better understanding of interactions between the tool and workpiece at welding temperature EDS line scans across the interfaces tool-workpiece after welding as well as after diffusion tests were performed. It was concluded that both tested ceramic-metal composites did not failure during multiple plunges and during the total transverse welding distance of 10 m. Also, significant tool wear was not observed after such a welding distance. The possibility of producing visually defect-free welds using tools from WC- and TiC- based ceramic-metal composites was proved and also mutual diffusion of elements across the interface tool-workpiece was discussed.

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Gassaa, Ramzi, Larbi Hemmouche, Riad Badji, Lionel Gilson, Luc Rabet, and Oussama Mimouni. "Effect of rotational speed and copper interlayer on the mechanical and fracture behaviour of friction stir spot welds of 5754 aluminium alloy." Metallurgical Research & Technology 120, no. 1 (2023): 118. http://dx.doi.org/10.1051/metal/2023014.

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The application of joining processes requires advanced mechanical tests to control the joints’ quality. Generally, welded sheets are verified using tensile shear tests. However, few studies also recommend conducting tension peel and cross-tension tests. The present work evaluates the mechanical behaviour of 5754 aluminium sheets jointed by friction stir spot welding (FSSW). The influence of the rotational speed on joint strength was first compared to riveted assemblies. Then, sheets welded with pure copper interlayers were compared to the precedents. The results indicated that, without an interlayer, lower and intermediate rotational speeds lead to higher mechanical strength under tensile shear tests compared to riveted assembly. However, it performed worse under tension peel and cross-tension tests at all studied rotational speeds. By adding copper, the strength of welded sheets is globally improved under tensile shear tests. Nevertheless, under tension peel and cross-tension tests, it performed worse, although a slight improvement was observed for increasing rotational speeds. Two different failure morphologies and four fracture modes were observed regarding the different tested samples. Microhardness tests were also conducted, to relate the influence of the studied parameters on the joint’s strength.

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Hollatz, Sören, Sebastian Kremer, Cem Ünlübayir, Dirk Uwe Sauer, Alexander Olowinsky, and Arnold Gillner. "Electrical Modelling and Investigation of Laser Beam Welded Joints for Lithium-Ion Batteries." Batteries 6, no. 2 (April 21, 2020): 24. http://dx.doi.org/10.3390/batteries6020024.

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The growing electrification of vehicles and tools increases the demand for low resistance contacts. Today’s batteries for electric vehicles consist of large quantities of single battery cells to reach the desired nominal voltage and energy. Each single cell needs a contacting of its cell terminals, which raises the necessity of an automated contacting process with low joint resistances to reduce the energy loss in the cell transitions. A capable joining process suitable for highly electrically conductive materials like copper or aluminium is the laser beam welding. This study contains the theoretical examination of the joint resistance and a simulation of the current flow dependent on the contacting welds’ position in an overlap configuration. The results are verified by examinations of laser-welded joints in a test bench environment. The investigations are analysing the influence of the shape and position of the weld seams as well as the influence of the laser welding parameters. The investigation identifies a tendency for current to flow predominantly through a contact’s edges. The use of a double weld seam with the largest possible distance greatly increases the joint’s conductivity, by leveraging this tendency and implementing a parallel connection. A simplistic increase of welded contact area does not only have a significantly smaller effect on the overall conductivity, but can eventually also reduce it.

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Tamadon, A., M. Abdali, D. J. Pons, and D. Clucas. "Characterization of Dissimilar Al-Cu BFSW Welds; Interfacial Microstructure, Flow Mechanism and Intermetallics Formation." Advances in Materials Science 20, no. 3 (September 1, 2020): 52–78. http://dx.doi.org/10.2478/adms-2020-0016.

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AbstractThe purpose of this study is to elucidate the flow features of the dissimilar Al-Cu welded plates. The welding method used is Bobbin Friction Stir Welding (BFSW), and the joint is between two dissimilar materials, aluminium alloy (AA6082-T6) and pure copper. Weld samples were cut from along the weld line, and the cross-sections were polished and observed under an optical microscope (OM). Particular regions of interest were examined under a scanning electron microscope (SEM) and analysed with Energy Dispersive X-ray Spectroscopy (EDS) using the AZtec software from Oxford Instruments. The results and images attained were compared to other similar studies. The reason for fracture was mainly attributed to the welding parameters used; a higher rotational speed may be required to achieve a successful BFSW between these two materials. The impact of welding parameters on the Al-Cu flow bonding and evolution of the intermetallic compounds were identified by studying the interfacial microstructure at the location of the tool action. The work makes an original contribution to identifying the solid-phase hybrid bonding in Al-Cu joints to improve the understanding of the flow behaviours during the BFSW welding process. The microstructural evolution of the dissimilar weld has made it possible to develop a physical model proposed for the flow failure mechanism.

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Muhammad, Najib A., and ChuanSong Wu. "Evaluation of capabilities of ultrasonic vibration on the surface, electrical and mechanical behaviours of aluminium to copper dissimilar friction stir welds." International Journal of Mechanical Sciences 183 (October 2020): 105784. http://dx.doi.org/10.1016/j.ijmecsci.2020.105784.

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Gurram, Mallaiah, Kumar Adepu, Ravinder Reddy Pinninti, and Madhusudhan Reddy Gankidi. "Effect of copper and aluminium addition on mechanical properties and corrosion behaviour of AISI 430 ferritic stainless steel gas tungsten arc welds." Journal of Materials Research and Technology 2, no. 3 (July 2013): 238–49. http://dx.doi.org/10.1016/j.jmrt.2013.02.009.

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Eslami, Nima, Yannik Hischer, Alexander Harms, Dennis Lauterbach, and Stefan Böhm. "Influence of Copper-Sided Tin Coating on the Weldability and Formation of Friction Stir Welded Aluminum-Copper-Joints." Metals 9, no. 2 (February 2, 2019): 179. http://dx.doi.org/10.3390/met9020179.

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Although the joining of aluminum and copper is a difficult task, several studies have shown that friction stir welding (FSW) is capable of producing aluminum-copper-joints with excellent performance. Therefore, it is desirable to use this joining technique for the production of cost- and weight-reduced conductors for the automotive sector. The exposed copper contact spots in automobiles are usually coated with tin for design reasons and in order to improve their corrosion resistance. In this context, it is possible to perform the weld at first and to coat afterwards, or to weld already coated copper workpieces. Taking this into account, this paper presents results on the influence of copper-sided tinning on the joint formation as well as the achievable mechanical and electrical properties of friction stir butt welded aluminum-copper joints. Two variants were considered. The first variant included copper blanks with a tinned surface. For the second variant the surface and the abutting edge of the copper were coated. The best welds achieved excellent electrical properties and their tensile strength was only slightly reduced compared to the aluminum base material. Thus, it was shown that if these tensile strength losses are acceptable, FSW of aluminum to tin coated copper is applicable.

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Bouarroudj, E., Wahiba Bouzidi, O. Menchi, and S. Abdi. "Effects of Copper Powder Insert Layer on the Properties of Friction Welded Joints Between AlCu and AISI 4140 Structural Steel." Defect and Diffusion Forum 283-286 (March 2009): 166–70. http://dx.doi.org/10.4028/www.scientific.net/ddf.283-286.166.

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The present investigation attempts to understand the friction welding characteristics of Aluminum alloy AlCu and steel AISI 4140. In spite, many trials were applied to achieve the sound weld zone of direct bonding between Aluminum and steel. The formation of intermetallic phase and crack in the near weld zone resulted in a lower tensile strength of joints relative to those of other welding technique. Therefore, to prevent intermetallic phase and crack formation at the interface, pure copper was used as insert powders for stress relief buffer layer. This study also envisages the influence of process parameters which include resident preform densities, friction pressure, upset pressure, and burn-off length on microstructure and mechanical properties of the welds. This work consolidates information on the aspects of diffusion joining of steel, copper and Aluminum component with wrought materials for practical execution. In the view point of tensile strength, the highest tensile strength between AlCu and AISI 4140 was acquired by using pure copper as insert powder.

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Flores, R. D., L. E. Murr, and E. A. Trillo. "Characterization o Solid-State Vortices Associated with the Friction-Stir Welding of Copper to Aluminum." Microscopy and Microanalysis 4, S2 (July 1998): 530–31. http://dx.doi.org/10.1017/s1431927600022777.

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Although friction-stir welding has been developing as a viable industrial joining process over the past decade, only little attention has been given to the elucidation of associated microstructures. We have recently produced welds of copper to 6061 aluminum alloy using the technique illustrated in Fig. 1. In this process, a steel tool rod (0.6 cm diameter) or head-pin (HP) traverses the seam of 0.64 cm thick plates of copper butted against 6061-T6 aluminum at a rate (T in Fig. 1) of 1 mm/s; and rotating at a speed (R in Fig. 1) of 650 rpm (Fig. 1). A rather remarkable welding of these two materials results at temperatures measured to be around 400°C for 6061-T6 aluminum welded to itself. Consequently, the metals are stirred into one another by extreme plastic deformation which universally seems to involve dynamic recrystallization in the actual weld zone. There is no melting.

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Kim, Jisun, Jeawoong Kim, and Inju Kim. "Analysis of welding properties using various horn-tip patterns in the ultrasonic metal welding process." Mechanics & Industry 21, no. 1 (2020): 102. http://dx.doi.org/10.1051/meca/2019078.

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The present study was conducted to investigate how the characteristics of welds are affected by the horn-tip pattern shape, in order to assess how to efficiently transfer the vibration energy to a base material through the horn. Energy transfer was evaluated using the indentation marks. The experiment was carried out with aluminum and copper by combining the conditions from four horn-tip patterns, six pressure values, and ten welding time values. The aspect ratio of the indentation marks on the weld surfaces was measured. The effects of the applied pressure, welding time, and horn-tip pattern shape on the aspect ratio were analyzed, and it was found that the horn-tip pattern shape affects the aspect ratio significantly. The aspect ratio was suggested as an analytical reference, and its correlations with the shear strength and the hardness of the welds were verified. In addition, the experiment performed with aluminum and copper, which have different mechanical properties, under the same welding conditions showed that the aspect ratio was dependent on the mechanical properties of the materials. In conclusion, as the density of the horn-tip pattern is decreased, less of the vibration energy was lost, increasing the strength of the welds. Experimental results showed that shear strength of copper was nearly 400 N when the aspect ratio was close to the value of 1. The highest peak of horn-tip pattern forms the lowest aspect ratio of the indentation mark, which can be indicated that the decrease of the aspect ratio effect to the improvement of welds strength. Aspect ratio of horn-tip pattern D, which dimensions are pitch 1.5 mm, height 0.75 mm and stub tooth 0.7 mm was closely to the value of 1 compared to the other patterns.

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Bian, Yanfei, SHI Jian-zhou, XIE Ming-jun, and CAI Meng. "A Study on the Joining Technology of Copper-Aluminium Composite Heat-Dissipating Components." Journal of Manufacturing Engineering 16, no. 2 (June 1, 2021): 066–69. http://dx.doi.org/10.37255/jme.v16i2pp066-069.

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Copper-aluminium composite heat dissipation components have both the high thermal conductivity of copper and the low density of aluminium. Copper and aluminium are dissimilar materials as they have significant differences in physical and chemical properties, and hence it is not easy to weld them together. In this paper, the joining of copper to aluminium is studied by using the ultrasonic brazing technique. The results show that the copper and aluminium can be connected by ultrasonic brazing, and it is found that the bonding of the copper side interface is the weak link of the entire joint, but the joint strength can still reach 95MPa.

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Wiedenhoft, Aldoni G., Heraldo J. Amorim, Tonilson S. Rosendo, and Telmo R. Strohaecker. "Friction Stir Welding of Dissimilar Al-Cu Lap Joints with Copper on Top." Key Engineering Materials 724 (December 2016): 71–76. http://dx.doi.org/10.4028/www.scientific.net/kem.724.71.

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Friction stir welding (FSW) is a solid state welding process that has been studied for dissimilar welding applications, especially aluminum and copper. However, the quality of dissimilar Al/Cu FSW joints is often impaired due to the formation of intermetallic compounds (IMCs), which affect both mechanical and electrical properties. This paper investigates the feasibility of FSW in producing dissimilar Al/Cu lap joints were copper is positioned over aluminum. In order to access the influence of rotational speed over the resulting joint, four different rotational speeds were tested for the same welding speed. The produced joints were then evaluated in terms of weld appearance, defects and the electrical resistance of the welded joints. Visual and ultrasound inspection indicated no discontinuity in any of the produced samples. Electrical resistance results indicate no influence of rotational speed. Moreover, electrical resistance of the Al/Cu FSW lap joints were smaller than the average between the electrical resistances of single metal joints welded with the tested materials in similar conditions. The experiments indicate that is possible to produce sound Al/Cu lap welds for the parameter window used, including the positioning of copper over aluminum, that is discouraged by literature. The small values of electrical resistance indicate no deleterious effect of IMCs over this characteristic.

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Kim, Jisun, Jaewoong Kim, In-ju Kim, Sungwook Kang, and Kwangsan Chun. "An Analysis of Mechanical Properties for Ultrasonically Welded Multiple C1220-Al1050 Layers." Applied Sciences 9, no. 19 (October 8, 2019): 4188. http://dx.doi.org/10.3390/app9194188.

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This study analyzed the characteristics of aluminum and copper sheets under multi-layer ultrasonic welding, and observed the strength, fracture type, and interface of the weld zone according to location. In addition, an experimental plan was developed using the Taguchi method to optimize the quadruple lap ultrasonic welding process conditions of 0.4t aluminum and copper sheets, and the experiment was performed for each of 25 welding condition. For strength evaluation, the ultrasonic welding performance was evaluated by measuring the tensile strength as a composite material and the shear force at the weld interface through two types of tensile tests: simultaneous tensile and individual tensile. To identify the individual shear strengths of the multi-layer dissimilar ultrasonic welds, three types of tensile tests were performed for each specimen depending on the location of the welded, and as the distance from the horn increased, each of shear strength decreased while the difference in strength value increased. For quadruple lap welding of pure aluminum and copper sheets, the S/N (Signal to Noise Ratio) was the highest at 64.48 with a coarse-grain pattern and optimal welding conditions, and this was selected as the optimal condition. To evaluate the optimized welding condition, additional tests were conducted using the welding conditions that showed the maximum strength values and the welding conditions optimized using the Taguchi method through simple tests. A strength evaluation of the optimized weldment was performed, and for a simultaneous tensile test, it was found that the strength of the optimized weldment was improved by 45% compared to other cases.

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Winarto, W., M. Anis, and B. Eka Febryansyah. "Mechanical and Microstructural Properties of Friction Stir Welded Dissimilar Aluminum Alloys and Pure Copper Joints." MATEC Web of Conferences 269 (2019): 01001. http://dx.doi.org/10.1051/matecconf/201926901001.

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Joining dissimilar metal alloys such as aluminum and copper is very difficult to be done because of alterations in chemical, metallurgical and physical behavior. Friction Stir Welding (FSW) is a solid-state welding technique which is one of the new methods used for joining the dissimilar metal. The material used is aluminum alloy 5052 and pure copper plates. The welding parameters were carried out with variable geometry shape of pin tools: taper and threaded cylindrical pin tools. Also preheating were performed on the part of copper plates with temperatures at both 25°C and 200°C. The friction stir welding of dissimilar joints was carried out at the rotary tool speed of 2800 rpm with the angle of 1 degree and the welding travel speed of 2 mm/sec. All welds were then carried out to several mechanical testing and microscopic observation. The results show that the variable geometry shape of pin tools and pre-heating on the copper part affect the microstructure grain size and the formation of Al-Cu inter-metallic phases. The creation of different structures influences the mechanical properties of the friction stir welds. The hardness of welds using threaded pin tools is higher than the tapper one. However, the tensile strength of dissimilar welds using the threaded cylindrical pin tools is lower than the tapper one. The fracture location commonly occurs at the part of aluminum plates having a brittle intermetallic phase.

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Coetsee, Theresa, and Frederik De De Bruin. "Chemical Behaviour of Copper in the Application of Unconstrained Cr-Ni-Al-Cu Metal Powders in Submerged Arc Welding: Gas Phase Thermodynamics and 3D Slag SEM Evidence." Processes 11, no. 2 (January 21, 2023): 351. http://dx.doi.org/10.3390/pr11020351.

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Unconstrained metal powders of Cu, Cr, Ni and Al were applied to submerged arc welding (SAW) to clarify the chemical behaviour of copper in this modified SAW process. Aluminium metal is avoided in SAW because it is easily oxidised. Excessive aluminium oxides in the form of slag or inclusions in the weld metal will lead to poor weld metal materials properties. Aluminium is an effective deoxidiser and can be used to prevent Cr and Ni loss to the slag by preventing oxidation of these metals. The results show that carbon steel was alloyed to 5.3% Cr, 5.3% Ni, 3.6% Al and 5.2% Cu at 80% Cr yield, 81% Ni yield, 54% Al yield and 79% Cu yield. BSE (backscattered electron) images of the three-dimensional (3D) post-weld slag sample show 3D structures within the slag dome. The 3D structures contain features of vapour formation and recondensation. In addition, nano-strands appear in the 3D structures and confirm the vaporisation and recondensation of fluorides. The chemical behaviour of copper metal powder added in SAW is to vaporise as metallic copper and incorporate in the Al-Si-Mg-Ca-Mn-Fe-Cu-Na-Cr-Ni fluoride. Copper, in combination with aluminium, has a stabiliser effect in SAW due to its formation of an initial alloy melt of low liquidus temperature, thus decreasing the temperature required to melt high-melting-point metals such as Cr into the weld pool. Although Al and Cu have similar vapour pressures at specific temperatures, it appears that Cu does not substitute for Al in the gas phase. Gas-slag-alloy thermochemical equilibrium calculations confirm the partial oxygen pressure lowering effect of aluminium and the vaporisation of copper as metallic copper with very little copper-fluoride species expected to form. The quantity of metallic copper vaporisation calculated in the gas-slag-alloy thermochemical equilibrium is much higher than the vaporisation quantity measured in welding. This may be due to recondensation of vaporised copper which is not accounted for in the equilibrium calculation at the set arc cavity temperature, as well as the effect of surface-active elements such as sulphur and oxygen in limiting the vaporisation reaction of copper.

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Mahdianikhotbesara, Ali, M. Hossein Sehhat, and Mohammadjafar Hadad. "A Numerical and Experimental Study into Thermal Behavior of Micro Friction Stir Welded Joints of Al 1050 and Copper Sheets." Advanced Materials Research 1170 (April 19, 2022): 49–60. http://dx.doi.org/10.4028/p-01ag12.

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One of the most important factors influencing the quality of the weld created by the micro friction stir welding is the amount of heat generated during the welding operation. Due to the lack of proper mixing of materials at low temperatures, joints' quality decreases due to the formation of cold welds. Also, overheating takes the process out of solid-state welding, which prevents good joints. Finite element analysis of friction stir welding leads to a better understanding of the effect of different parameters on the process. With the results extracted from such analysis, some of the output can be predicted, such as heat distribution. In the present study, in order to perform finite element analysis of the micro friction stir welding of Al 1050 to pure copper, the coupled Eulerian-Lagrangian method in Abaqus software has been used. The results of finite element analysis showed that the heat distribution on the copper side is wider due to the higher heat transfer coefficient of copper than aluminum. The maximum temperature in the analysis was recorded in the weld line, which was 392°C. The heat generated during the welding process was measured at different points relative to the joint line, and appropriate matching was observed with a comparison of experiments and simulation results.

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Eslami, Nima, Alexander Harms, Johann Deringer, Andreas Fricke, and Stefan Böhm. "Dissimilar Friction Stir Butt Welding of Aluminum and Copper with Cross-Section Adjustment for Current-Carrying Components." Metals 8, no. 9 (August 24, 2018): 661. http://dx.doi.org/10.3390/met8090661.

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Manufacturing dissimilar joints of aluminum and copper is a challenging task. However, friction stir welding (FSW) was found to be a suitable technique to produce aluminum–copper joints. Due to different electrical conductivities between aluminum and copper, an adjustment of the cross-section is required to realize electrical conductors free of resistive losses. Taking this into account, this paper presents initial results on the mechanical and electrical properties of friction stir butt welded aluminum and copper blanks having thicknesses of 4.7 mm and 3 mm, respectively. Three different approaches were investigated with the aim to produce sound welds with properties similar to those of the used base materials. Friction stir welding has been conducted at a welding speed of 450 mm/min. Subsequently, the welded specimens were subjected to metallographic analysis, tensile testing, and measurements of the electrical conductivity. The ultimate tensile force of the best joints was about 10 kN, which corresponds to joint efficiencies of approximately 72% of the aluminum base material. The analysis of electrical joint properties led to very promising results, so that the potential of FSW of Al–Cu butt joints with sheets having different thicknesses could be confirmed by the investigations carried out.

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Chapke, Yashwant, Dinesh Kamble, and Saoud Md Salim Shaikh. "Friction welding of Aluminium Alloy 6063 with copper." E3S Web of Conferences 170 (2020): 02004. http://dx.doi.org/10.1051/e3sconf/202017002004.

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Friction welding process is a forging welding process in which work piece are joined due to heat produced by friction between two joining surfaces and upset pressure is applied by non-rotating work piece. Joining of aluminum alloy with dissimilar material is important research area to focus on as maximum aircraft structures havexx Aluminum alloy frame and aerospace designers familiar with Aluminum alloy and its design considerations. After comparison of mechanical properties and application of light weight alloys aluminum alloys, tungsten, stainless steel and copper, copper selected as dissimilar material to join with Aluminum alloy AA6063. AA 6063 also known as architectural alloy selected based upon its properties. This dissimilar joint of AA6063 and Copper has application in electrical conductors as copper is good electrical conductivity and used in maximum electrical conductors. In this research work AA6063 joined with Copper successfully using Rotary Friction Welding process. Through process study effective process parameters like Friction Pressure, Upset Pressure, Spindle Speed, and Friction Time identified and their effect on weld joint strength were studied.Testing for measuring UTS of friction welded joint conducted. Using DOE tool optimized set process parameters for friction welding identified and their effect on weld joint strength studied experimentally. Maximum UTS of 222.787 MPa for Friction welded joint achieved, bend test also performed on friction welded samples.

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Muzakki, Hakam, Ikrom Millaily, Ahmadi, Suwarsono, and Jefri S. Bale. "Macrostructure and Shear Strength Analysis on Cu-Al Joint of Micro Friction Stir Spot Welding." Key Engineering Materials 943 (March 29, 2023): 41–46. http://dx.doi.org/10.4028/p-xco4h9.

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Efficiency energy is an importance goal in transportation device development. Reducing weight of device is a way to reduce fuel consumption from transportation device, using thin plat in a device or construction could reduce the weight. The originality of this study was Micro Dissimilar Friction Stir Spot welding used to join Cu and Al plate with copper sheet on top the aluminum sheet. Micro welding is a joining thin plat less than 1 mm welded by Friction Stir Spot welding which has been called a Micro Friction Stir Spot welding, using a Pin on the Shoulder. Peak load average, macrostructure and shear strength of a copper and aluminum sheet joint welded by Micro Friction Stir Spot welding were discussed in this study. Copper and Aluminum 0.5 mm could be successfully joined. Shoulder diameter 6 mm effected to the highest peak load, and welding force 50 kgf significantly increased the peak load. Mixing Cu and Al formed in a weld joint. Friction was not complete occurred in shoulder interface and deflection copper sheet formed in around weld nugget because of Pin and Shoulder. A Pin on Shoulder affect to form a joint only around Pin, shear strength could not conclude because the weld joint areas developing tend to an incomplete joining.

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Sahul, Miroslav, Martin Sahul, Matej Pašák, and Milan Marônek. "ANALYSIS OF THE PROPERTIES OF AW2099 ALUMINIUM-LITHIUM ALLOY WELDED BY LASER BEAM WITH AW5087 ALUMINIUM-MAGNESIUM FILLER MATERIAL." Acta Polytechnica 59, no. 6 (December 31, 2019): 580–86. http://dx.doi.org/10.14311/ap.2019.59.0580.

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EN AW2099 aluminium lithium alloy, 2.0mm in thickness, was used as an experimental material. EN AW2099 belongs to the 3rd generation of aluminium lithium alloys. The third generation was developed to improve the disadvantages of the previous generation, such as anisotropy in mechanical properties, low fracture toughness, corrosion resistance and resistance to fatigue crack growth, as well. Aluminium magnesium 5087 filler wire with a diameter of 1.2mm was used for the welding. Crack free weld joints were produced after an optimization of welding parameters. The microstructure of weld metal and mechanical properties of weld joints were investigated. Equiaxed zone (EQZ) was observed at the fusion boundary. The character of grains changed in the direction towards the weld centre, from the columnar dendrite zone to equiaxed dendrite zone in the weld centre. The microstructure of the weld metal matrix consisted of -aluminium. Alloying elements enrichment was found at the inter-dendritic areas, namely copper and magnesium. The microhardness decrease in the weld metal due to a dissolution of strengthening precipitates was measured. The microhardness was slightly higher in comparison to a weld produced by a laser welding without a filler material. The tensile strength of the weld joint reached around 67% of the base material’s strength and the fracture occurred in the weld metal.

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Kaspar, Joerg, M. Zimmermann, A. Ostwaldt, G. Goebel, J. Standfuß, and B. Brenner. "Challenges in Joining Aluminium with Copper for Applications in Electro Mobility." Materials Science Forum 783-786 (May 2014): 1747–52. http://dx.doi.org/10.4028/www.scientific.net/msf.783-786.1747.

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The effective joining of aluminium with copper is one of the central technical goals involved in electro mobility. However, the joining of both metals by conventional fusion welding is challenging because of poor weldability arising from different chemical, mechanical and thermal properties of the materials and especially from the massive formation of hard and brittle intermetallic compounds (IMC) weld interface. In order to accomplish the difficult task of joining aluminium and copper several new joining technologies and strategies such as Laser Beam Welding (LBW) using highly dynamic beam deflection, Friction Stir Welding (FSW), Laser Induction Roll Plating (LIRP) and Electromagnetic Pulse Welding (EMPW) are under development at the Fraunhofer IWS. The current work describes the different technological approaches to the dissimilar joining of aluminium and copper. Thereby, the different joining technologies are compared with respect to weld quality. Special consideration is given to the study of interface morphology and microstructure of the welding zone. It will be shown that, depending on the joining method chosen the kind and extension of intermetallic phase formation differs considerably. Conclusions are drawn with respect to the applicability of the different joining methods.

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Elanchezhian, C., B. Vijaya Ramnath, R. Saisundararam, V. Ramanan, C. S. Siddarth, P. Kandeepa Thondaiman, V. Maurya Sundar, and S. Mohammed Sadiq. "Investigating the Weld Strength of AA7075 Aluminium Alloy for TIG, MIG and FSW Welding." Applied Mechanics and Materials 766-767 (June 2015): 727–32. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.727.

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The main objective of this work is to compare the weld strength of AA7075 aluminium alloy by conducting tensile test and impact test for various welding like TIG, MIG and FSW. Aluminium is one of the lightest available commercial metals with a density approximately one third that of steel or copper, thus making it the most earnestly used metal for Catamaran ferries, petroleum tankers and aircrafts. Having so many welding methods for joining AA7075 alloy, it is still unclear as to which welding method gives the better weld strength. This study shows the best suitable method of welding for AA7075 aluminium alloy for the suitable conditions specified. ANOVA is done to find the parameters that have highest influence on weld strength. The result shows that the parameter that has highest influence on weld strength is axial force.

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Venkata Ramana, V. S. N., Raffi Mohammed, G. Madhusudhan Reddy, and K. Srinivasa Rao. "Effect of Post Weld Heat Treatment on Corrosion Behavior of AA2014 Aluminum – Copper Alloy Electron Beam Welds." IOP Conference Series: Materials Science and Engineering 330 (March 2018): 012052. http://dx.doi.org/10.1088/1757-899x/330/1/012052.

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Panaskar, Nitin, and Ravi Prakash Terkar. "Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design." World Journal of Engineering 17, no. 4 (May 11, 2020): 491–507. http://dx.doi.org/10.1108/wje-11-2019-0322.

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Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

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Singh, Arun Pratap, and Dr Shahnawaz Alam. "Wire Feed Rate Optimization for MIG Welding of Alu-minum Alloy 6063." International Journal of Advanced Engineering, Management and Science 8, no. 7 (2022): 01–13. http://dx.doi.org/10.22161/ijaems.87.1.

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MIG welding (metal inert gas welding) is an arc welding technology that generates metal coalescences by heating them with an arc between a filler metallic electrode that is constantly fed, and the work. MIG welding process lends itself to semiautomatic, robotic automation and difficult automation welding packages. The alloy fabric variety for GMAW consists of carbon steel, chrome steel, aluminium (Al), magnesium (Mg), copper (Cu), nickel (Ni), and silicon bronze. This experimental study aims at optimization of the wire feed rate during MIG weld of aluminium sheets by developing the mathematically model for the tensile strength a hardness of the aluminium specimen. In this experiment Factorial design approach has been implemented for locating connection among diverse procedure parameters and weld deposit reason. MIG Welding of aluminium alloy 6063 with Al 4043 Wire and Argon gas shielding yields excellent results.

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Kaisheva, Darina, Angel Anchev, Vladimir Dunchev, Georgi Kotlarski, Borislav Stoyanov, Maria Ormanova, and Stefan Valkov. "Electron-Beam Welding Cu and Al6082T6 Aluminum Alloys with Circular Beam Oscillations." Crystals 12, no. 12 (December 4, 2022): 1757. http://dx.doi.org/10.3390/cryst12121757.

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In this study, we present the results from electron-beam welding operations applied on copper and Al6082T6 aluminum alloys. The influence of beam-scanning geometries on the structure and mechanical properties of the welded joint is studied. The experiments were conducted using a circle oscillation mode with an oscillation radius of 0.1 mm and 0.2 mm. The beam deflection was set to 0.4 mm with respect to the side of the aluminum alloy, and the beam power was set at 2700 W. The phase composition of the obtained welded joints was studied by X-ray diffraction (XRD). Scanning electron microscopy (SEM) was used for the investigation of the microstructure of the joints. The chemical composition was investigated by using energy-dispersive X-ray spectroscopy (EDX). The mechanical properties were studied by micro-hardness investigations. The fusion zone of the weld seam contains three phases—an aluminum matrix, an ordered solid solution of copper and aluminum in the form of CuAl2, and pure copper. Electron beam-scanning geometries have significant influences on the structure of the weld. Increasing the beam oscillation’s radius leads to a decrease in intermetallic phases and improves homogeneity. The measured microhardness values in the fusion zone are much higher than the ones measured in the base metals due to the formation of intermetallic phases. The microhardness of the weld joint formed using an oscillation radius of 0.2 mm was much lower compared to the one formed using an oscillation radius of 0.1 mm.

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Journal articles on the topic 'Aluminium - copper welds'

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