Study of the welding conditions during similar and dissimilar aluminium and copper welding based on torque sensitivity analysis

Abstract The aim of present study was to analyse and compare the influence of the welding conditions on torque evolution, during similar and dissimilar friction stir butt welding of 5083-H111 aluminium alloy and copper-DHP. The torque registered during welding, using different welding parameters and base materials combinations, and its relation with the morphological and structural properties of the welds were analysed. Independently of the materials to be welded and the relative plates positioning, in dissimilar friction stir welding, the sensitivity of the average torque to the process parameters was observed to be the same. It was also observed that the average torque is strongly conditioned by the materials to be welded, since, for all welding parameters, the lowest average torque values were always registered during dissimilar welding. Material flow and intermetallic-formation were found to determine this behaviour. Important differences in instantaneous torque evolution, during welding, were also observed depending on base materials combinations.

[1]  Alvin M. Strauss,et al.  Torque control of friction stir welding for manufacturing and automation , 2010 .

[2]  Philip J. Withers,et al.  Dissimilar friction stir welds in AA5083-AA6082. Part I: Process parameter effects on thermal history and weld properties , 2006 .

[3]  R. M. Leal,et al.  Microstructural and mechanical characterisation of 5XXX-H111 friction stir welded tailored blanks , 2011 .

[4]  H. Bhadeshia,et al.  Friction stir welding of dissimilar alloys – a perspective , 2010 .

[5]  Pedro Vilaça,et al.  Effect of shoulder cavity and welding parameters on friction stir welding of thin copper sheets , 2011 .

[6]  Altino Loureiro,et al.  Material flow in heterogeneous friction stir welding of aluminium and copper thin sheets , 2010 .

[7]  Radovan Kovacevic,et al.  Microstructural evolution in the friction stir welded 6061 aluminum alloy (T6-temper condition) to copper , 2006 .

[8]  Jun Shen,et al.  Microstructural characterisation and mechanical properties of friction stir welded joints of aluminium alloy to copper , 2011 .

[9]  Dulce Maria Rodrigues,et al.  Determination of local constitutive properties of aluminium friction stir welds using digital image correlation , 2012 .

[10]  A. Loureiro,et al.  Formation and distribution of brittle structures in friction stir welding of aluminium and copper: influence of process parameters , 2011 .

[11]  Joseph D. Robson,et al.  A model relating tool torque and its associated power and specific energy to rotation and forward speeds during friction stir welding/processing , 2010 .

[12]  B. Xiao,et al.  Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al-Cu joints , 2011 .

[13]  V. Firouzdor,et al.  Al-to-Mg Friction Stir Welding: Effect of Material Position, Travel Speed, and Rotation Speed , 2010 .

[14]  Anthony P. Reynolds,et al.  Torque, Power Requirement and Stir Zone Geometry in Friction Stir Welding Through Modeling and Experiments , 2009 .

[15]  A. Loureiro,et al.  Formation and distribution of brittle structures in friction stir welding of aluminium and copper: Influence of shoulder geometry , 2012 .

[16]  D. Rodrigues,et al.  Analysis of high temperature plastic behaviour and its relation with weldability in friction stir welding for aluminium alloys AA5083-H111 and AA6082-T6 , 2012 .