Influences of shape of the new interfaces and morphology of the intermetallics on mechanical properties of aluminum AA2024�pure copper joints by friction stir welding

Anbukkarasi, R and Kailas, S V (2020) Influences of shape of the new interfaces and morphology of the intermetallics on mechanical properties of aluminum AA2024�pure copper joints by friction stir welding. In: International Journal of Advanced Manufacturing Technology, 106 (11-12). pp. 5071-5083.

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Abstract

Friction stir welding (FSW) joints are inevitably accompanied with the change in shape of the abutting surfaces due to the tool movement. Further, the formation of brittle intermetallics (during dissimilar welding) is also unavoidable. Therefore, the current work is focused to study the role of the shape of the new interface in properties of the joints and to control the morphology of intermetallics subsequently. FSW experiments were carried out between aluminum AA2024 and pure copper for different tool offset positions (on either side of the interface), plate positions (copper in advancing or retreating side), and tool geometry (plain and threaded). The microstructure observation showed noticeable changes in the shape of the new interface with respect to the selected parameters. Tensile tests highlighted that the weld which has continuous and smooth new interface gave better properties than the welds which had an irregular discontinuous interface. Also, this kind of interfaces had formed with a continuous thin intermetallic layer, and it was a desirable morphology of the intermetallics. The weld with this thin intermetallic layer (metallurgical bonding) alone has the maximum strength, whereas the welds that also had fine steps at the interface (mechanical bonding from interlocking effect) have maximum ductility. The mechanism behind this was explained in detail with the help of material flow behavior study for the selected conditions. This concluded that to achieve better properties, the shape of the new interface and the bonding along this interface are mainly important to be considered.

Item Type:	Journal Article
Publication:	International Journal of Advanced Manufacturing Technology
Publisher:	Springer
Additional Information:	The copyright for this article belongs to Springer
Keywords:	Aluminum alloys; Copper; Friction; Intermetallics; Mechanical properties; Morphology; Research laboratories; Tensile testing; Welds, Dissimilar weld; Interface bonding; Interface shape; Material Flow; Tool offset, Friction stir welding
Department/Centre:	Division of Mechanical Sciences > Mechanical Engineering
Date Deposited:	27 Aug 2020 04:13
Last Modified:	27 Aug 2020 04:13
URI:	http://eprints.iisc.ac.in/id/eprint/64878

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