Heterogeneous friction stir welding: Improved properties in dissimilar aluminum alloy joints through insertion of copper coupled with external heating

Publication Type:
Journal Article
Materials and Manufacturing Processes, 2012, 27 (12), pp. 1429 - 1436
Issue Date:
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Friction stir welding (FSW) experiments are conducted on AA7075 and AA6061 alloys under optimized conditions with copper as intermediate inclusion on the faying sides of the base material assisted by external heating from the root side during the process. The concept behind the experimentation is to minimize the temperature gradient that exists between the top and bottom sides of the plates. The work attempts to relocate the crack initiation point from the root of the retreating side, as in conventional friction stir weldments due to the variation in material flow along the weld cross-section. Analysis of the formed intermetallic compound (IMC) indicates that the interaction of AA7075, AA6061 alloys with copper, in coating form, enhances the bond strength by formation of Al 2 Cu and Al 4 Cu 9 IMCs. High thermal conductivity of the copper in coating form along with external heating from the root side has minimized the temperature gradient and maintains homogenous material flow in the weld zone and increased bond strength. © 2012 Copyright Taylor and Francis Group, LLC.
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