Influence of FSW process on dissimilar T-joint of aluminum alloy to pure copper

This work investigated the influence of friction stir welding (FSW) parameter on forming the dissimilar T-joint of aluminum alloy 6061 (AA6061) to pure copper (C1100). The experimental outcomes indicated that the hook formation trended to move toward the center of welding line at low welding and/or...

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Bibliographic Details
Published in:Materials and manufacturing processes 2025-01, Vol.40 (2), p.263-273
Main Authors: Duong, Hao Dinh, Van Phi, Thuyen, Hung Tran, Tra
Format: Article
Language:English
Subjects:
AA6061
defect
diffusion
FSW
interface
intermetallic
microstructure
strength
T-joint
Welding
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Summary:This work investigated the influence of friction stir welding (FSW) parameter on forming the dissimilar T-joint of aluminum alloy 6061 (AA6061) to pure copper (C1100). The experimental outcomes indicated that the hook formation trended to move toward the center of welding line at low welding and/or high rotational speeds. In all cases, the kissing bond (KB) defects were significantly observed in advancing (AS) compared to retreating sides (RS). The thickness of diffusion and intermetallic compound (IMC) layers decreased with increasing welding and/or decreasing rotational speeds. A highest joint efficiency was attained with approximately 74% at 500/125 rev/mm of the skin test and 34% at 500/100 rev/mm of the stringer tests. The fracture process under the stringer test initiated from the AS to the RS along the interface while that of the skin test cracked in the heat affected zone. Improving dissimilar T-joint of AA6061/C1100 was impacted not only by controlling the KB defect but also the IMC layer thickness.
ISSN:1042-6914
1532-2475
DOI:10.1080/10426914.2024.2406771