Prediction and validation of intermetallic compound formation during friction stir welding of AA6061 to commercially pure copper

Gihad Karrar, Alexander Galloway, Athanasios Toumpis, Fadi Al-Badour, Hongjun Li

Research output: Contribution to journalArticlepeer-review

Abstract

A novel approach for predicting the intermetallic compound (IMC) formation during friction stir welding (FSW) of AA6061 to commercially pure copper has been developed, in addition to their effect on mechanical properties. The temperature distribution of the aluminium to copper weld nugget determined by a finite element model, the use of an Al–Cu phase diagram and the elemental concentration of copper and aluminium in the weld nugget have been combined to predict and validate several IMCs present in the different zones of the weldment. The results of performing butt-welding of these dissimilar metals using the FSW process demonstrated that the highest ultimate tensile strength of 194.5 MPa was achieved at 1500 rev min −1 tool rotational speed, 100 mm min −1 traverse speed and a zero-tool offset.

Original languageEnglish
Number of pages14
JournalScience and Technology of Welding and Joining
Early online date28 Mar 2022
DOIs
Publication statusE-pub ahead of print - 28 Mar 2022

Keywords

  • intermetallic compounds
  • friction stir welding
  • joint integrity
  • dissimilar joining
  • modelling
  • metallurgy

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