FRACTURE BEHAVIOR AND MECHANICAL PERFORMANCE OF DISSIMILAR FRICTION STIR CLINCHED CU/AL JOINT
DOI:
https://doi.org/10.51459/futajeet.2022.16.1.391Keywords:
Friction stir clinching, copper alloy, aluminum alloy, microstructure, mechanical properties, fractureAbstract
The friction stir clinching (FSC) of C10100 and AA5456 alloys was investigated to improve the weld performance of the Al/Cu joint via the combined effect of protrusion-induced mechanical interlocking and metallurgical bonding. The microstructure, tensile, and fracture results of the friction stir clinched C10100/AA5456 joints were studied. The in-situ local temperature histories of the joints were recorded via the use of K-type thermocouples connected to a data logger. The peak temperatures of the joints at 900 rpm, 1120 rpm, and 1400 rpm are 332.4oC, 399.8oC, and 577.1oC respectively. The increase in the plunge depth (0.5 -1.5 mm) increases the amount of the extruded surface flash and the weld failure load of the joint while the increase in the tool rotational speed (900 - 1400 rpm) hampers the resultant failure load of the joint. The highest and the least failure loads of the joints are 2282 N and 1060 N respectively. The fracture modes of the joints include partially sheared protrusion, completely sheared protrusion, and undamaged protrusion/protrusion pullout. The completely sheared protrusion fracture mode produced the maximum failure load owing to the combined effect of protrusion-induced interlocking and metallurgical bonding. It is recommended to weld Al and Cu alloys at low tool rotational speed and high plunge depth for desirable metallurgical bond and Al/Cu interlock.
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