Chinese Journal of Mechanical Engineering >

2021 , Vol. 34 >Issue 4: 75 - 75

DOI: https://doi.org/10.1186/s10033-021-00593-0

Intelligent Manufacturing Technology

Refill Friction Stir Spot Welding Al Alloy to Copper via Pure Metallurgical Joining Mechanism

  • Zhikang Shen ,
  • Yuquan Ding ,
  • Wei Guo ,
  • Wentao Hou ,
  • Xiaochao Liu ,
  • Haiyan Chen ,
  • Fenjun Liu ,
  • Wenya Li ,
  • Adrian Gerlich
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  • 1. School of Materials Science and Engineering, Northwestern Polytechnical University, Xi'an 710072, China;
    2. Centre for Advance Materials Joining, University of Waterloo, Waterloo N2L 3G1, Canada;
    3. College of Energy Engineering, Yulin University, Yulin 719000, China

收稿日期: 2020-03-10

  修回日期: 2020-12-29

  网络出版日期: 2021-12-21

基金资助

Supported by National Natural Science Foundation of China (Grant Nos. 51975479, 51905437), Fundamental Research Funds for the Central Universities (Grant No. 3102019QD0404), Science and Technology Bureau of Yulin (Grant No. 2019-86-1), and High-Level Talent Project of Yulin University, China (Grant No. 20GK06)

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Refill Friction Stir Spot Welding Al Alloy to Copper via Pure Metallurgical Joining Mechanism

  • Zhikang Shen ,
  • Yuquan Ding ,
  • Wei Guo ,
  • Wentao Hou ,
  • Xiaochao Liu ,
  • Haiyan Chen ,
  • Fenjun Liu ,
  • Wenya Li ,
  • Adrian Gerlich
Expand
  • 1. School of Materials Science and Engineering, Northwestern Polytechnical University, Xi'an 710072, China;
    2. Centre for Advance Materials Joining, University of Waterloo, Waterloo N2L 3G1, Canada;
    3. College of Energy Engineering, Yulin University, Yulin 719000, China

Received date: 2020-03-10

  Revised date: 2020-12-29

  Online published: 2021-12-21

Supported by

Supported by National Natural Science Foundation of China (Grant Nos. 51975479, 51905437), Fundamental Research Funds for the Central Universities (Grant No. 3102019QD0404), Science and Technology Bureau of Yulin (Grant No. 2019-86-1), and High-Level Talent Project of Yulin University, China (Grant No. 20GK06)

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摘要

The current investigation of refill friction stir spot welding (refill FSSW) Al alloy to copper primarily involved plunging the tool into bottom copper sheet to achieve both metallurgical and mechanical interfacial bonding. Compared to conventional FSSW and pinless FSSW, weld strength can be significantly improved by using this method. Nevertheless, tool wear is a critical issue during refill FSSW. In this study, defect-free Al/copper dissimilar welds were successfully fabricated using refill FSSW by only plunging the tool into top Al alloy sheet. Overall, two types of continuous and ultra-thin intermetallic compounds (IMCs) layers were identified at the whole Al/copper interface. Also, strong evidence of melting and resolidification was observed in the localized region. The peak temperature obtained at the center of Al/copper interface was 591 ℃, and the heating rate reached up to 916 ℃/s during the sleeve penetration phase. A softened weld region was produced via refill FSSW process, the hardness profile exhibited a W-shaped appearance along middle thickness of top Al alloy. The weld lap shear load was insensitive to the welding condition, whose scatter was rather small. The fracture path exclusively propagated along the IMCs layer of Cu9Al4 under the external lap shear loadings, both CuAl2 and Cu9Al4 were detected on the fractured surface on the copper side. This research indicated that acceptable weld strength can be achieved via pure metallurgical joining mechanism, which has significant potential for the industrial applications.

关键词： Refill friction stir spot welding; Al alloy; Copper; Interfacial microstructure; Mechanical properties

本文引用格式

Zhikang Shen , Yuquan Ding , Wei Guo , Wentao Hou , Xiaochao Liu , Haiyan Chen , Fenjun Liu , Wenya Li , Adrian Gerlich . Refill Friction Stir Spot Welding Al Alloy to Copper via Pure Metallurgical Joining Mechanism[J]. Chinese Journal of Mechanical Engineering, 2021 , 34(4) : 75 -75 . DOI: 10.1186/s10033-021-00593-0

Abstract

The current investigation of refill friction stir spot welding (refill FSSW) Al alloy to copper primarily involved plunging the tool into bottom copper sheet to achieve both metallurgical and mechanical interfacial bonding. Compared to conventional FSSW and pinless FSSW, weld strength can be significantly improved by using this method. Nevertheless, tool wear is a critical issue during refill FSSW. In this study, defect-free Al/copper dissimilar welds were successfully fabricated using refill FSSW by only plunging the tool into top Al alloy sheet. Overall, two types of continuous and ultra-thin intermetallic compounds (IMCs) layers were identified at the whole Al/copper interface. Also, strong evidence of melting and resolidification was observed in the localized region. The peak temperature obtained at the center of Al/copper interface was 591 ℃, and the heating rate reached up to 916 ℃/s during the sleeve penetration phase. A softened weld region was produced via refill FSSW process, the hardness profile exhibited a W-shaped appearance along middle thickness of top Al alloy. The weld lap shear load was insensitive to the welding condition, whose scatter was rather small. The fracture path exclusively propagated along the IMCs layer of Cu9Al4 under the external lap shear loadings, both CuAl2 and Cu9Al4 were detected on the fractured surface on the copper side. This research indicated that acceptable weld strength can be achieved via pure metallurgical joining mechanism, which has significant potential for the industrial applications.

Key words： Refill friction stir spot welding; Al alloy; Copper; Interfacial microstructure; Mechanical properties

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