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DOI 10.1007/s00170-009-2443-7
ORIGINAL ARTICLE
Received: 1 July 2008 / Accepted: 10 November 2009 / Published online: 27 November 2009
# Springer-Verlag London Limited 2009
Abstract Industrial use of non-ferrous materials is significant in the electrical and the chemical engineering
applications. Copperaluminium joints are inevitable for
certain applications due to unique performances such as
higher electric conductivity, heat conductivity, corrosion
resistance and mechanical properties. Friction welding is
the most common method used due to material and energy
saving. In the present study, copper and aluminium
materials were joined by friction welding. Optimum
parameters were obtained using a statistical approach.
Tensile and microhardness tests were applied to the joints.
Micro- and macrophotographs were examined. Energy
dispersive X-ray analysis was used to determine the phases
that occurred during welding. A grey layer was observed at
the fracture surfaces of welded parts. It was considered that
this layer decreased the strength of the joints.
Keywords Welding strength . Friction welding . Copper .
Aluminium
1 Introduction
The most important problem in friction welding of
dissimilar materials is a brittle intermetallic phase at the
joint interface. This is due to the fact that the intermetallic
phase existing at joint interface reduces the strength of the
welded parts. Aluminium and copper are replacing steels
in electricity supply systems due to higher electric
M. Sahin (*)
Mechanical Engineering Department of Trakya University,
22180 Edirne, Turkey
e-mail: mumins@trakya.edu.tr
528
5
1
1.
2.
3.
4.
5.
6.
7.
Motor
Brake
Rotating Chuck
Non Rotating Chuck
Rotating Workpiece
Non Rotating Workpiece
Hydraulic Cylinder
2
3
Parameters
Welding
Started
Time
Welding
Completed
Pb (%)
<0.00200
Sn (%)
0.00222
<0.00100
Zn (%)
0.00137
P (%)
<0.00050
Mn (%)
Aluminium
Pb (%)
0.03360
Sn (%)
0.00500
1.14000
Zn (%)
0.11800
Mn (%)
0.57400
Fe (%)
Copper
0.01220
Ni (%)
0.0381
Fe (%)
0.55400
Si (%)
<0.00100
Ni (%)
0.17100
Mg (%)
0.00745
Si (%)
0.00300
Sb (%)
0.00376
Mg (%)
0.02420
Cr (%)
0.00500
Al (%)
0.01340
Ti (%)
<0.00050
Bi (%)
0.59300
Cu (%)
0.00251
S (%)
96.76000
Al (%)
<0.00200
Sb (%)
300
Tensile strength
(MPa)
200
99.93
Cu
(%)
530
T, s (rpm)
Pf (MPa) , tf (sec)
Lathe
Chuck
Aluminium
Aluminium
Copper
Friction
Time
(tf)
Friction
Pressure
(Pf)
Upset
Time
(tu)
Upset
Pressure
(Pu)
d1 (mm)
10
d2 (mm)
10
(s)
2.5
(MPa)
60
(s)
15
(MPa)
120
Copper
1
2
3
4
5
6
7
8
9
10
Friction
pressure
(MPa)
X1
Upset
pressure
(MPa)
X2
Friction
time (s)
42
42
60
60
48
48
48
60
60
60
80
96
120
120
96
80
100
80
105
110
6
10
2.5
5
7.5
4
5
3
10
10
X3
Tensile
strength
(MPa)
TS
90
120
140
133
110
100
103
125
70
50
531
Copper
Aluminium
x5
532
Copper
Aluminium
x5
(4) and (5) illustrate the EDX analysis results taken from the
points 1, 2, 3 and 4, respectively. Table 5 shows the EDS
point analysis results represented by SEM. The EDS
results confirm that CuAl joints contain some intermetallic compounds. Formation of these brittle intermetallic
compounds degrades the strength of the joints [6, 14].
4.4 Hardness variations of welded parts
5 Conclusions
In the present study, continuous drive friction welding
was successfully adopted to weld copper and aluminium
together. The welding process was investigated by
statistical analysis, tensile testing, microstructural observation, EDS measurements and hardness testing. As a
result:
&
&
533
Copper
Side
Aluminium
Side
x 1000
25.0kV
25.0kV
Points
Elements
Line
Intensity (c/s)
Al
Fe
Cu
Ka
Ka
Ka
1,054.36
36.54
15.65
Al
Ka
1,013.86
Al
V
Fe
Cu
Ka
Ka
Ka
Ka
891.13
0.96
23.84
65.64
Cu
Ka
883.70
Cu
Ka
790.24
100.0
100.0 um
um
Conclusion (total)
89.113
6.523
4.364
100.000
100.000
100.000
80.581
0.115
3.537
15.767
wt.%
wt.%
wt.%
wt.%
wt.%
wt.%
wt.%
wt.%
wt.%
wt.%
100.000
100.000
100.000
100.000
100.000
wt.%
wt.%
wt.%
wt.%
wt.%
534
References
150
Copper
Side
Aluminium
Side
125
100
75
50
25
0
-4
-3
-2
-1
&
&