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EVALUATION OF ELECTRO-MECHANICAL
PROPERTIES OF FRICTION STIR WELDED AL
/ CU BIMETALLIC LAP JOINTS
Dr. M. Satya Narayana Gupta
Professor, Department of Aeronautical Engineering,
MLR Institute of technology, Hyderabad, India
K. Shiva Shankar
Assistant Professor, Department of Aeronautical Engineering,
MLR Institute of Technology, Hyderabad, India
ABSTRACT
Friction stir welding Processes (FSWP) is a sophisticated solid state welding
technology to join dissimilar and similar materials. Commercially pure Aluminium and
Copper plates were joined using FSWP and the mechanical and electrical properties
of bimetallic lap joints have been evaluated by changing the input processes
parameters. Number of experiments was performed to obtain the optimum joint
properties by adjusting angle of tool tilting, rotational and welding speeds. The
experiments were carried out using design of experiments (DoE) to minimize number
of experiments. The present paper provides a very valuable information on electro-
mechanical behavior of Al to Cu dissimilar joints used for a critical application i.e.
heat sinks, high voltage bus bars and heavy duty earthing strips, etc. It has been
observed that high quality welds are obtained at low rotational and welding speeds
irrespective of tilting angle. The maximum value of tensile shear strength is 70 MPa.
The hardness is uniform throughout the joint. In manufacturing condition the resistance
of the joint is negligible.
Key words: Friction Stir Welding, Dissimilar Metals, Lap Joints, Mechanical
Properties, Electrical Resistance.
Cite this Article: Dr. M. Satya Narayana Gupta and K. Shiva Shankar, Evaluation of
Electro-Mechanical Properties of Friction Stir Welded Al / Cu Bimetallic Lap Joints.
International Journal of Civil Engineering and Technology, 8(4), 2017, pp. 1967-1976
http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=4
1. INTRODUCTION
Due to the rapid increase in Copper cost, the manufacturers of electronics and electrical
equipment manufactures prefer to replace the Cu with Al in many applications [1] like heat
shinks, heavy duty busbars, high duty earthing strips, panel boards etc. Different parameters
influence the selection of conductor material for heavy duty current bus systems. Generally, Al
is taken for one side of the system and Cu for another side. The transition have been made,
where the two conductors meets. Originally, bolted joints were used to made transition pieces
[2, 3]. Because of difficulty in making electrically reliable and stable bolted joints in between
Al and Cu metals, in last decade most of the researchers were focused on making transitions
using bonded Cu to Al materials.
Welding of Al/Cu is generally utilized as a transition piece as a part of high current transport
frameworks to transmit the current. From the perspective of the welding procedure, Al and Cu
are incongruent metals to welding since they have a high fondness to each other, at a
temperature more than 120 0C and create fragile intermetallics [4, 5] that is mechanically and
electrically shaky, in light of the fact that these intermetallic mixes have a nonmetallic
covalence band. Hence, an endeavor to weld Al to Cu by routine means through the use of heat
energy, to dissolve and fuse, the two metals can bring about a temperamental weld. The regular
procedure to achieve this metallic bond has been to plate Al with another metal. This practice
includes many stages, is environmentally not friendly and is utilized for only little joints.
Explosion welding, friction and friction stir welding have been considered as the qualified
welding procedure of these metals because of reliable joint interface and little intermetallic
development.
Friction stir joining is a lot of versatile, compared to all or any different solid state joining
methods, in welding parts rather massive or complex in shape [6]. This welding method is a
novel solid state welding method in which the metal that is being welded doesnt melt and
recast7. In this joining process, the plates to be welded are firmly clamped in position. FSW
tool is a rotating non-consumable tool with specially designed pin and shoulder. This tool
penetrates into the two parts to be joined until the tool shoulder touches the top overlap part
and moves along the required weld seam as represented in figure1.
The main aim of this paper is to test the weldability of Cu/Al lap joints fabricated by FSW
and to evaluate the electro-mechanical properties of the weld by changing input parameters
such as rotational speed of tool, speed of welding and the tilting angle.
2. EXPERIMENTAL PROCEDURE
The pure Copper and Aluminium plates of size 150mm x 100mm x 3mm were used to fabricate
FSW Cu/Al lap joints.
Tables 1a and 1b represents the mechanical and chemical properties of the parent materials.
The relative positions of Cu and Al plates for FSW are shown in figure2. In this work, single
pass welding processes used for fabrication of lap joints. High speed tool M2 of hardness Rc62
has been used for welding. The taper pin tool geometry and material chemical composition is
given in table 2a and 2b. The friction stir welding machine is shown in figure4. This machine
has an arrangement for adjustment of angle of tilt, welding speed, rotating speed of tool,
frictional time and speed of plunging.
L1 _ _ _ 70 Al base metal
L2 + _ _ 41 Interface
L3 _ + _ 55 Interface
L4 + + _ 52 Interface
L5 _ _ + 68 Al base metal
L6 + _ + 46 Interface
L7 _ + + 30 Interface
L8 + + + 40 Interface
As specified by the design matrix, eight lap joints have been fabricated. The welded joints
are sliced using a shear cutting machine and then machined to the required size as shown in
figure 5. The tensile shear specimens are prepared as per the ASTM D-1002 standard to
evaluate the tensile shear strength of the welded joints. Tensile shear strength of the FSW lap
joints is evaluated by conducting shear test on universal testing machine (UTM). The
consistency of the results has been checked by repeating the experiment L1 four times. The
standard deviation and variance were calculated for these four experiments as 1.515 and 2.296
respectively. This value is much less than the standard deviation of eight treatment
combinations i.e 13.88
Figure 6. Simplified Schematic Representation of The Setup Used to Measure Resistance Of Al/Cu
Bimetallic Lap Joints
(a)
(b)
Figure 8 Failure locations at a) N =1500 rpm, V=30 mm/min and A = 00 b) N =1500 rpm, V=30
mm/min and A = 30
heat affected zone (HAZ) of both the advancing and retreating side. This shows the local
softening of the material in HAZ, because of the thermal action of the welding processes. The
hardness of the nugget was higher than that of HAZ and the base metal. This may be attributed
to the formation of brittle and hard intermetallic compound and very fine recrystallized grains
in the nugget zone and grain growth in HAZ[9,10] .
Figure 9 Micro hardness distribution for the joint produced by N=1500rpm and v = 80 mm/min
The hardness in longitudinal direction also performed near interface and top of the plates
in order to know uniformity of the joint. The measurement results in longitudinal direction are
shown in the figure10 and figure11. The hardness results indicate that the hardness has been
uniform throughout the joint. This indicates that the joint is uniform from the beginning to the
end of the joint. At some points high hardness (120 and 168) has been observed this is due to
the inter-metallic compound Al3Cu9.
Figure10 Hardness distribution of longitudinal section in Al plate near interface and top of the plate
Figure11 Hardness distribution of longitudinal section in Cu plate near interface and top of the plate
4. CONCLUSIONS
Sound lap joints of Al/Cu have been successfully obtained by friction stir welding technology.
Joint fabricated at low rotational speed and low welding speed yielded superior tensile shear
strength irrespective of tilting angle and the failure was in base metal Aluminum. The
maximum value of tensile shear strength was 70 MPa. It is about 100% of base metal
aluminium and 70% of base metal Copper. The minimum hardness in Al and Cu was found in
the heat affected zone (HAZ) of both the advancing and retreating side. The joint is uniform
from the beginning to the end of the joint. The joint resistance is essentially negligible as in
manufactured condition
5. ACKNOWLEDGEMENTS
The authors would like to acknowledge the help by M/S DMRL, Hyderabad and M/S BHEL
R&D, Hyderabad for giving permission to conduct experiments on friction stir welding
machine and to measure joint resistance respectively.
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