Friction Stir Lap Welding of Aluminum alloy to Copper: Improvement of the joint efficiency by using intermediate layer

Lap joint friction stir welding (FSW) between dissimilar Cu and Al alloys was investigated. To produce the better quality welds, a layer of Cu was anodized on the aluminum alloy. The mechanical and the micro-structural characterization are also performed on the welds produced with varying welding parameters. Scanning Electron Microscope (SEM) with Energy- Dispersive X-ray Spectroscopy (EDS) was used to identify the elemental compositions of phases formed. The results showed that using the copper anodized layer prevented forming the brittle IMCs and displayed an approximate increase of 25% to the shear strength of the direct welds. Furthermore, in the indirect welds, the highest shear strength was obtained at welding speed of 25mm/min and rotational speed of 1120 RPM, while the highest strength of direct welds was obtained at rotational speed of 1400RPM.

کلیدواژه ها:

Friction stir welding ، Intermediate layer ، Microstructure ، Shear test