Tensile strength and hardness correlations with microscopy in friction welded aluminium to copper

R Satish, V Seshagiri Rao… - Journal of The Institution …, 2016 - Springer
Journal of The Institution of Engineers (India): Series C, 2016Springer
Aluminium and copper are good conductors of heat and electricity, copper being the better
conductor, is a costly metal indeed. On the other hand, aluminium is cheap, easily available
and also has a lower density than copper. Hence, worldwide efforts are being made to
partially replace copper wire. Solid state welding should be used to join aluminium to
copper. This is because the use of fusion welding results in brittle phases formed in the weld
interface. One of the solid state welding techniques used for joining aluminium to copper is …
Abstract
Aluminium and copper are good conductors of heat and electricity, copper being the better conductor, is a costly metal indeed. On the other hand, aluminium is cheap, easily available and also has a lower density than copper. Hence, worldwide efforts are being made to partially replace copper wire. Solid state welding should be used to join aluminium to copper. This is because the use of fusion welding results in brittle phases formed in the weld interface. One of the solid state welding techniques used for joining aluminium to copper is friction welding. In this paper, an attempt has been made to join aluminium to copper by friction welding by varying the friction welding parameters, namely friction pressure, upset pressure, burn-off length and speed of rotation of the workpiece. Nine different friction welding parameter combinations were used during welding in accordance with ASTM standards and results have been reported. Tensile strength and hardness tests were carried out for each parameter combination. Optimum friction welding parameter combination was identified with respect to tensile strength. Scanning Electron Microscopy and Electron dispersive spectroanalysis were obtained to identify modes of fracture and presence of intermetallic phases for each friction welding combination with the aim to narrow down friction welding parameters that give good properties on the whole.
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