Effect of friction spot welding parameters on the joint formation and mechanical properties of Al to Cu

• Published in: Welding in the world Vol. 63; no. 1; pp. 33 - 41
• Main Authors: Cardillo, Maria E. B., Shen, Junjun, de Alcântara, Nelson G., Afonso, Conrado R. M., dos Santos, Jorge F.
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01-01-2019; Springer Nature B.V
• Subjects: Aluminum; Chemistry and Materials Science; Copper; Deformation; Dissimilar material joining; Dissimilar materials; Factorial design; Materials Science; Mechanical properties; Metallic Materials; Research Paper; Shear strength; Solid Mechanics; Spot welding; Theoretical and Applied Mechanics; Welding parameters; Dissimilar; Mechanical properties; Microstructures; Friction spot welding (refill friction stir spot welding); Copper; Aluminum
• ISSN: 0043-2288; 1878-6669
• DOI: 10.1007/s40194-018-0632-4

Friction spot welding is an appealing technique for joining dissimilar materials, such as aluminum and copper that have significant differences in physical and mechanical properties. To optimize the welding process, a full-factorial design was employed. It is found that in addition to the plunge depth, the interaction between the rotational speed and the plunge depth significantly influences the lap-shear strength of the Al/Cu dissimilar joints. Further investigations on macro- and microstructures show that increasing the plunge depth could deform the Cu sheet into a concave shape to form a mechanical interlocking, and thus increase the joint lap-shear strength; increasing the tool rotational speed, however, may compromise this effect because of the formed tunnel defects on the interface due to high thermal exposure.