Achieving High-Quality Aluminum to Copper Dissimilar Metals Joint via Friction Stir Double-Riveting Welding

doi:10.1007/s40195-022-01512-5

Abstract

Abstract:

In order to achieve a high-quality joining of aluminum (Al) and copper (Cu) dissimilar metals, a new friction stir double-riveting welding (FSDRW) with a Cu rod as the rivet was proposed, and the rotating tool with a large concave angle shoulder was specially designed. The results showed that under the thermal-mechanical effect of rotating tool, the Cu rod was deformed to be a double riveting heads structure with a Cu anchor at the upper surface of Al plate and an Al anchor above the lap interface of joint, and these two anchors greatly enhanced the mechanical interlocking of Al/Cu joint. The effective bonding interfaces were formed among the double riveting heads structure, the upper Al plate and the lower Cu plate, which contained the Cu/Cu interface and the Al/Cu interface. The Cu/Cu interface without the kissing bond and the Al/Cu interface with the rationally thin AlCu and Al₂Cu intermetallic compounds (IMCs) layers were beneficial to heightening the joint tensile shear strength. The maximum tensile shear load of the FSDRW joint achieved 5.52 kN, and the joint under different plunging depths of rotating tool presented a mixed mode of ductile fracture and brittle fracture. This novel FSDRW technique owns the advantages of strong mechanical interlocking and superb metallurgical bonding, and provides a new approach to acquiring a high-quality Al/Cu dissimilar metals joint.

Key words: Al/Cu dissimilar metals joint, Friction stir double-riveting welding, Bonding interface, Mechanical interlocking, Tensile shear load

Shude Ji, Xiao Cui, Lin Ma, Hua Liu, Yingying Zuo, Zhiqing Zhang. Achieving High-Quality Aluminum to Copper Dissimilar Metals Joint via Friction Stir Double-Riveting Welding[J]. Acta Metallurgica Sinica (English Letters), 2023, 36(4): 552-572.

Figures/Tables 25

Fig. 1 Schematics of FSDRW process: a drilling stage; b plunging stage; c dwelling stage; d retracting

Fig. 2 Schematics of a rotating tool, b tensile shear sample

Table 1 Process parameters during FSDRW

Rotational velocity (r/min)	Plunging velocity (mm/min)	Dwell time (s)	PD (mm)
1200	2	15	0 0.1 0.2

Fig. 3 a Mesh generation used in this study, b schematic diagram of temperature measurement positions

Fig. 4 Surfaces of joints a before welding, b after welding

Fig. 5 Cross-sections of joints at different PDs: a 0 mm, b 0.1 mm, c 0.2 mm

Table 2 Geometric parameters of the double riveting heads structure at different PDs

PD (mm)	L_upsetting (mm)	H_c (mm)	L_c (mm)	H_a (mm)	L_a (mm)	H_c/L_c	H_a/L_a
0	8.95	1.15	2.98	0.66	0.71	0.39	0.93
0.1	9.06	1.61	3.63	0.65	0.54	0.45	1.20
0.2	9.26	1.69	3.64	0.60	0.45	0.46	1.33

Fig. 6 Microstructures of BMs of a Cu rod, b Cu plate, c Al plate; microstructures of typical areas d K1, e K2, f K3 near the original Cu/Cu lap interface marked in Fig. 5; microstructures of areas g SZ1, h SZ2, i SZ3 marked in Fig. 5b

Fig. 7 a Temperature cycles of points P1 and P2 by numerical simulation; b peak temperatures of point P1 and P2 by numerical and experimental methods

Fig. 8 a Temperature fields at 120 s at 0.1 mm PD; b peak temperatures of points B1, B2 and B3 at the Al/Cu interfaces

Fig. 9 Interfacial formations of typical regions of joints under different PDs: a-e enlarged views of A1-E1 marked in Fig. 5a; f-j enlarged views of A2-E2 marked in Fig. 5b; k-o enlarged views of A3-E3 marked in Fig. 5c

Fig. 10 EDS results of a G2 marked in Fig. 5b, b H2 marked in Fig. 5b, c H3 marked in Fig. 5c; XRD of Al/Cu interface under different of PDs: d 0.1 mm, e 0.2 mm; schematics of the interfacial microstructures of f vertical Al/Cu and g Cu anchor interfaces

Table 3 EDS results of scanning spots marked in Figs. 10 and 11

Location	Atomic percent (at%)		Composition
Location	Al	Cu	Composition
1	0.52	99.48	Cu
2	48.21	50.79	AlCu
3	42.98	57.03	AlCu
4	71.27	28.73	Al₂Cu
5	69.50	30.50	Al₂Cu
6	99.53	0.47	Al
7	47.61	53.39	AlCu
8	60.36	39.64	Al₂Cu
9	72.72	28.28	Al₂Cu
10	67.65	32.35	Al₂Cu
11	96.34	3.66	Al

Fig. 11 Interfacial formations of typical regions of joints under different PDs: a I2 marked in Fig. 5b, b enlarged view of area B marked in Fig. 11a; c I3 marked in Fig. 5c, d enlarged view of area D marked in Fig. 11c

Fig. 12 Enlarged views of F2 and F1 marked in Fig. 5 and line scanning results under different PDs: a 0.1 mm, b 0 mm; enlarged views of G2 and G3 marked in Fig. 5 and line scanning results under different PDs: c 0.1 mm, d 0.2 mm; enlarged views of H2 and H3 marked in Fig. 5 and line scanning results under different PDs: e 0.1 mm, f 0.2 mm

Table 4 IMC layer thicknesses and atomic diffusion layer thicknesses of Al/Cu interfaces under different PDs

	PD (mm)	IMC (μm)	Diffusion thickness (μm)
Lap Al/Cu interface	0	1.39	2.70
Lap Al/Cu interface	0.1	2.79	3.90
Vertical Al/Cu interface	0.1	5.53	8.40
Vertical Al/Cu interface	0.2	6.92	9.20
Cu anchor interface	0.1	3.29	5.00
Cu anchor interface	0.2	4.17	9.50

Fig. 13 a Schematics of the hardness measured points; hardness distributions of b line A, c line B at different PDs, d line C at 0.1 mm PD

Fig. 14 Tensile shear loads and Hc/Lc and Ha/La values of joints under different PDs

Fig. 15 a Local views of shear-fractured Cu plate and Al plate; enlarged views of zones b B, c C, d D, e E, f F, g G marked in Fig. 15a

Fig. 16 a Local views of shear-plug fractured Cu plate and Al plate; enlarged views of zones b B, c C, d D, e E, f F, g G marked in Fig. 16a

Fig. 17 Schematics of interfacial microstructure evolution during FSDRW: a Cu anchor interface, b lap Al/Cu interface and c vertical Al/Cu interface

Fig. 18 Schematics of FSDRW joint formations under the plunging depths of tool shoulder of a − 0.2 mm, b 0 mm, c 0.1 mm, d 0.2 mm

Fig. 19 Schematics of FSDRW joint under different tensile forces: a very low, b low, c high

Fig. 20 Schematics of fracture paths of a shear fracture mode, b shear-plug fracture

Fig. 21 Tensile shear strengths of Al/Cu dissimilar metals joint by solid-state spot welding

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