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J. Mater. Sci. Technol., 2013, -(-), 1e9
In this study, AA 1050 aluminum alloy and commercially pure copper in annealed and severely plastic deformed
conditions were used. The technique used for imposing the severe strain to the sheets was constrained groove
pressing (CGP) process. The annealed and severely plastic deformed sheets were subjected to friction stir
welding (FSW) at different rotation and traverse speeds. Cu was placed in advancing side. Constant offset of
approximately 1 mm was used toward Al side for all welds. A range of welding parameters which can lead to
acceptable welds with appropriate mechanical properties was found. For the FSWed CGPed samples, it was
observed that the welding heat input caused grain growth and decrease in hardness value at Al side of the
stir zone. It was found that, generally the weakest parts of weld joints of annealed and CGPed samples were
Al base metal and stir zone, respectively. Further investigations showed that several forms of intermetallic
compounds were produced.
KEY WORDS: Friction stir welding; Severe plastic deformation; Aluminum; Copper; Intermetallics
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No. Sheet metals Thickness Welding parameters Offset (mm) Tool parameters Ref.
(mm)
Rotation Traverse Tilt angle Pin diameter Shoulder
speed (r/min) speed (mm/min) (deg.) (mm) diameter (mm)
Materials Al Fe Si Zn Pb Ni Cu
et al.[16,18] investigated inuence of process parameters and made from H13 tool-steel. The tilt angle of the tool was 2.5 . Cu,
shoulder geometry on formation and distribution of brittle which was the harder material, was placed in advancing side and
compounds in FSW of aluminum and copper. the tool pin had constant offset about 1 mm toward the Al side.
There are many process parameters, such as rotation speed, FSW was conducted at rotation speeds of 600, 800, 900, 1000,
traverse speed and tool offsetting that inuence the weld prop- 1200 and 1400 r/min, and traverse speeds of 50, 63, 80, 100 and
erties of the dissimilar FSW joints. Recently, it is well docu- 125 mm/min. For microstructure analysis, transversal sections of
mented that during FSW of dissimilar material, the harder welds were prepared and chemically etched to reveal the
material should be placed in advancing side. It is also reported microstructure of different zones. Al side of the welds was
that during the FSW of dissimilar materials, the tool pin should electro-etched by 10 ml HBF4 200 ml distilled water at a
have a constant offset toward the softer material[20]. For instance, voltage of 26 V for 80 s and grain structure was revealed by
Xue et al.[17] achieved defect-free welds between 1060 using polarized light. Afterward, the copper side was etched with
aluminum and commercially pure copper by using the tool pin a solution of 5 g FeCl2 50 ml HCl 100 ml H2O. Scanning
offset toward aluminum. A brief summary of all previous studies electron microscopy (SEM) complemented by energy dispersive
on dissimilar FSW of Al and Cu alloys is illustrated in Table 1. It X-ray spectroscopy (EDS) was also used in order to examine the
is obvious that there is no unanimous agreement on welding more delicate structure formed in the stir zone.
parameters, which can make defect-free joints, and a wide range To evaluate mechanical properties of the specimens after FSW
for rotation and traverse speeds have been reported. process, transverse tensile and microhardness prole tests were
In this study, AA 1050 aluminum alloy and commercially pure performed. According to the ASTM E8M standard, three tensile
copper in annealed and CGPed conditions were subjected to butt specimens were cut from the mid-length of the welds. Tensile
FSW. The mechanical properties and microstructures of FSWed tests were carried out using an Instron machine operating at a
specimens were investigated. The aim of this study is to nd a speed of 1 mm/min. The Vickers microhardness test was carried
range of welding parameters and subsequently a range of heat out on the centerline of cross-section perpendicular to the
input, which can produce acceptable welds with appropriate welding direction, using 1 N load for 15 s.
mechanical properties for both annealed and CGPed samples.
3. Results and Discussion
2. Experimental
3.1. Selection of appropriate heat-input range
AA 1050 aluminum and commercially pure copper sheets
with dimension of 84 mm 50 mm 3 mm were used. Table 2 According to Table 1, previous studies on FSW of Al to Cu do
shows the chemical composition of these materials. Al and Cu not show unanimous agreement of suitable welding parameters.
sheets were annealed at 350 C and 650 C, respectively. Some Therefore, in this study, wide ranges of rotation speeds from 600
of the Al and Cu sheets were subjected to CGP process. In each
pass of this process effective strain of 1.16 was imposed to the Table 3 Mechanical properties of used materials
sheet[21]. In this study specimens were subjected to 2 passes of
CGP process. The mechanical properties of used materials before Mechanical Annealed Al CGPed Al Annealed Cu CGPed Cu
welding process can be seen in Table 3. properties
FSW machine was used to dissimilar butt weld of the samples
UTS (MPa) 72 115 210 300
in annealed and 2 passes CGPed conditions. Welding tool had Hardness (HV) 25 45 57 93
15 mm-diameter shoulder and 3 mm-diameter pin, which was
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H. Barekatain et al.: J. Mater. Sci. Technol., 2013, -(-), 1e9 3
Fig. 2 Surface morphologies of AleCu FSW joints in annealed and CGPed conditions at different welding parameters, with constant pin offset of
approximately 1 mm.
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Table 4 UTS and place of fracture of AleCu FSW joints in annealed and CGPed conditions at different welding parameters, with constant pin offset of
approximately 1 mm
Welding parameters u/V ((r/min)/(mm/min)) Annealed (MPa) Place of fracture (for annealed) CGPed (MPa) Place of fracture
(for CGPed)
1400 r/mine63 mm/min are the best parameters; because their As can be seen in Table 4, the aforementioned welding pa-
correlate weldments have not only higher comparable UTS, rameters have a specic u/V range, from 17.5 to 22.22 (r/min)/
but also they have the least weld defect and in some cases no (mm/min). Therefore, it can be realized that comparatively
defects. For example annealed samples at welding parameters of acceptable FSWed joints between Al and Cu, in annealed and
1200 r/mine63 mm/min and CGPed samples at welding pa- CGPed conditions, can be achieved with aforementioned u/V
rameters of 1400 r/mine63 mm/min do not have any defects. ratio range. It also can be understood that welding parameters
with u/V ratio of higher than 22.22 (r/min)/(mm/min) and less
than 17.5 (r/min)/(mm/min), cannot provide comparatively
acceptable joints; because they produce higher and lesser heat-
input values, respectively, than what is needed to have accept-
able joints in annealed and CGPed samples.
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Fig. 5 Microstructures of initial materials: (a) annealed Al, (b) annealed Cu.
Fig. 6, in which no defect such as void can be found. The stir The microhardness prole of FSW joint of annealed samples
zone consists of a detached Cu layer, surrounded by Al. at welding parameters of 1200 r/mine63 mm/min is presented in
Considering Fig. 7(a), it can be observed that the average Fig. 8. The hardness value of stir zone is higher than that of Al
grain size in the stir zone is ner than that in the base metal. This base metal, because the materials in the stir zone are exposed to
grain renement during FSW process leads to greater hardness in SPD and subsequent recrystallization[2], which caused a very
the stir zone in comparison with hardness of Al base metal, ne grain structure in the weld region (Fig. 7(a)). The hardness
which can be seen in Fig. 8. Regarding Fig. 7(a), elongated value of stir zone is higher than that of Al base metal caused by
grains in TMAZ (thermo-mechanical-affected zone) of Cu which grain renement; but this hardness value is lower than that of Cu
can be observed in TMAZ of Al, cannot be seen. This phe- base metal.
nomenon is in line with previous studies[2,25]. Fig. 9 shows the SEM backscattered electron images (BEI) of
FSWed CGPed sample at welding parameters of u 1200 r/min
and V 63 mm/min. As shown in Fig. 9(a), the stir zone consists of
a mixture of aluminum matrix and Cu particles. Some voids can
also be observed in this image. Fig. 9(b) shows a magnied view of
the rectangular region in Fig. 9(a), and Fig. 9(c) shows a contin-
uous intermetallic layer in AleCu interface. Intermetallic com-
pounds are seen in different forms in the stir zone. The rst type of
these compounds is in form of membranes encircling Cu particles
(layer A), which have been dispersed through the stir zone during
Fig. 6 Macrostructure of weld joint of annealed samples at u FSW. According to EDS analysis of phases shown in Fig. 10, this
1200 r/min and V 63 mm/min. layer consists of Al4Cu9. This intermetallic compound is always
surrounded by another intermetallic compound (layer B). EDS
analysis reveals that the ratio of aluminum atoms to copper is about
1.85. It suggests that this layer is Al2Cu. It is obvious that layer B
contains more Al than layer A. According to the AleCu binary
equilibrium phase diagram[26], there are various intermetallic
compounds, involving Al2Cu, AlCu, Al3Cu4 and Al4Cu9, which
may be developed during the Al/Cu reaction. Xue et al.[15] have
observed AlCu in AleCu stir zone. On the contrary, AlCu is not
observed in the present study. This fact is in fully agreement with
data reported for dissimilar FSW of Al and Cu[13,25,27], where
Al2Cu and Al4Cu9 are the most probable intermetallic compounds
that can be developed in the stir zone. Another type of these
compounds is formed as a continuous and uniform layer (layer C)
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Fig. 9 SEM backscattered electron images (BEI) of the CGPed Al and Cu samples FSWed at u 1200 r/min and V 63 mm/min: (a) cross-sectional
macrograph of the joint, (b) magnied view of the rectangular region in (a), and (c) microstructure of the AleCu interface.
in AleCu interface with a thickness of about 0.6 mm. Considering side is lower than that of Al base metal, which may be due to
XRD results of AleCu interface, Xue et al.[15] reported that this grain growth in HAZ leading to lower UTS.
layer is composed of Al2Cu and Al4Cu9. Fig. 13 shows the SEM BEIs of FSWed annealed samples at
Fig. 11 shows the microstructure of stir zone of the FSWed welding parameters of u 1400 r/min and V 63 mm/min. In
CGPed Al and Cu samples at welding parameters of u 1200 r/ bottom of the weld joint, large volume of IMC layers have
min and V 63 mm/min in Al and Cu sides. As can be seen in developed. These layers have hardness values ranging from 126
Fig. 4(f) and Fig. 9(a), the stir zone consists of large Cu particles
and layers. These Cu layers have a high hardness value about
160 HV. This is probably developed due to SPD during FSW
process and producing a high dislocation density; that is why a
high hardness value can be seen in Fig. 12.
The UTS of the FSWed CGPed Al and Cu samples at welding
parameters of u 1200 r/min and V 63 mm/min is 80 MPa.
The weld is fractured from HAZ of Al side. According to
microhardness of this sample, the hardness value of HAZ in Al
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Fig. 13 SEM backscattered electron images (BEI) of the annealed Al and Cu samples FSWed at u 1400 r/min and V 63 mm/min: (a) cross-
sectional macrograph of bottom the joint, (b) magnied view of the rectangular region in (a).
to 195 HV. Ouyang et al.[13] reported that in dissimilar FSW of annealing on yield strength of two passes CGPed copper sheet.
Al 6061 to copper, different microhardness levels, from 136 to They reported that the yield strength increases with increasing
760 HV, were produced in weld stir zone corresponding to annealing temperature due to grain renement resulted from
various microstructures and material ow patterns. Fig. 14 shows recrystallization phenomenon. At this stage, increase in grain
macrostructure and microstructure of CGPed sample at welding boundary density compensates the decrease of dislocation den-
parameters of u 1400 r/min and V 63 mm/min. No defect sity and leads to increase of the strength.
can be found in this weld joint. A great deal of grain renement Fig. 15 shows microhardness of annealed and CGPed sample
can be seen in weld zone in Cu side, in comparison with Cu base at welding parameters of u 1400 r/min and V 63 mm/min.
metal. It can be caused by dynamic recrystallization in Cu. Microhardness values of base metal of CGPed samples are
Moreover, Razadeh et al.[28] investigated the effect of post- higher than those of base metal of annealed samples; but these
Fig. 14 OM images of dissimilar FSW of CGPed samples at u 1400 r/min and V 63 mm/min: (a) macrostructure of joint, (b)e(e) microstructures
of different regions marked as AeD in (a).
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values are relatively the same in the stir zones of both cases. (1) AA 1050 aluminum alloy and commercially pure copper
FSW is a thermomechanical process that joins materials, with has been joined successfully by FSW in annealed and
imposing SPD at high temperature. It not only can produce CGPed conditions.
higher hardness in SZ (stir zone) of annealed samples, due to (2) There is a range of heat input, in which both annealed and
grain renement and recrystallization phenomena, but also can CGPed samples can be joined together successfully.
reduce the hardness of SZ in SPDed materials due to their un- (3) Several forms of intermetallic compounds are found in weld
stable structure upon heating. Sun et al.[5] and Khorrami et al.[6] zone of FSWed annealed and CGPed samples. These
reported this phenomenon in FSW of SPDed aluminum alloys. compounds mainly consist of Al2Cu and Al4Cu9.
The microstructure of annealed and CGPed samples at weld- (4) Relative reduction in stir zone hardness value of CGPed
ing parameters of u 1400 r/min and V 80 mm/min, can be sample can be found, while for annealed sample it is
seen in Fig. 4(k) and (l), respectively. SZs consist of Cu particles increased compared with their BM due to grain renement.
detached from Cu base metal during FSW. These Cu particles are (5) Regarding tensile test results, generally the weakest part of
surrounded by lots of IMCs layers. Fig. 16 shows XRD results of weld joints of annealed and CGPed samples are Al base
annealed and CGPed samples at welding parameters of metal and stir zone, respectively.
u 1400 r/min and V 80 mm/min. Both of the weld joints
contain Al2Cu and Al4Cu9. Fig. 17 shows microhardness prole
Acknowledgments
The authors thank the Research Board of Sharif University
of Technology and Tamkar Industrial Company for the nancial
support and the provision of the research facilities used in this
study.
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