搅拌头形状对异质搅拌摩擦焊铜铝接头性能的影响（英文）
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摘要
其余的工艺参数保持不变的条件下研究了9种不同形状搅拌头对异质搅拌摩擦焊铜铝接头性能的影响。采用宏观组织、显微组织、拉伸试验、硬度、扫描电子显微镜和电子X射线光谱仪等力学和冶金方法评估异质接头的性能。结果表明,采用直径为8 mm的圆柱形搅拌头得到的接头强度最大。此外,当多边形搅拌头的边数减少时,碎屑缺陷增加,因此,多边形接头不适合异质搅拌摩擦焊对接接头。而且,当多边形搅拌接头边数增加时,抗拉强度也随之增大。对同一焊肩表面,相对于圆柱形的搅拌头,多边形搅拌头的搅拌区较硬脆。采用多边形搅拌头得到的焊缝的最大硬度为HV 283。在搅拌区明显存在硬脆金属间化合物。在异质铜铝接头搅拌区存在金属间化合物,如Cu Al、Cu Al_2、Cu_3Al和Cu_9Al_4。
Dissimilar friction stir welding(FSW) of copper and aluminum was investigated by nine different tool designs, while the rest of the process parameters were kept constant. Mechanical and metallurgical tests such as macrostructure, microstructure, tensile test, hardness, scanning electron microscope and electron X-ray spectrographs were performed to assess the properties of dissimilar joints. The results exhibited that, the maximum joint strength was achieved by the tool of cylindrical pin profile having 8 mm pin diameter. Besides, the fragmental defects increased as the number of polygonal edges decreased, hence the polygonal pin profiles were unsuitable for dissimilar FSW butt joints. Furthermore, the tensile strength increased as the number of polygonal edges increased. Stir zone of polygonal pin profiles was hard and brittle relative to cylindrical tool pin profiles for same shoulder surface. Maximum hardness of HV 283 was obtained at weld made by the polygonal square pin profile. The hard and brittle intermetallic compounds(IMCs) were prominently presented in the stir zone. Phases of IMCs such as CuAl, CuAl_2, Cu_3Al and Cu_9Al_4 were presented in the stir zone of dissimilar Cu-Al joints.
Dissimilar friction stir welding(FSW) of copper and aluminum was investigated by nine different tool designs, while the rest of the process parameters were kept constant. Mechanical and metallurgical tests such as macrostructure, microstructure, tensile test, hardness, scanning electron microscope and electron X-ray spectrographs were performed to assess the properties of dissimilar joints. The results exhibited that, the maximum joint strength was achieved by the tool of cylindrical pin profile having 8 mm pin diameter. Besides, the fragmental defects increased as the number of polygonal edges decreased, hence the polygonal pin profiles were unsuitable for dissimilar FSW butt joints. Furthermore, the tensile strength increased as the number of polygonal edges increased. Stir zone of polygonal pin profiles was hard and brittle relative to cylindrical tool pin profiles for same shoulder surface. Maximum hardness of HV 283 was obtained at weld made by the polygonal square pin profile. The hard and brittle intermetallic compounds(IMCs) were prominently presented in the stir zone. Phases of IMCs such as CuAl, CuAl_2, Cu_3Al and Cu_9Al_4 were presented in the stir zone of dissimilar Cu-Al joints.
引文
[1]MEHTA K P,BADHEKA V J.A review on dissimilar friction stir welding of copper to aluminum:process,properties,and variants[J].Materials and Manufacturing Processes,2016,31(3):233-254.
[2]MEHTA K P,BADHEKA V J.Influence of tool design and process parameters on dissimilar friction stir welding of copper to AA6061-T651 joints[J].Int J Adv Manuf Technol,2015,80(9):2073-2082.
[3]MISHRA R S,MA Z.Friction stir welding and processing[J].Materials Science and Engineering:R:Reports,2005,50(1):1-78.
[4]LOHWASSER D,CHEN Z.Friction stir welding:From basics to applications[M].Elsevier,2009.
[5]RAI R,DE A,BHADESHIA H,DEBROY T.Review:Friction stir welding tools[J].Science and Technology of Welding and Joining,2011,16(4):325-342.
[6]ESMAEILI A,RAJANI H Z,SHARBATI M,GIVI M B,SHAMANIAN M.The role of rotation speed on intermetallic compounds formation and mechanical behavior of friction stir welded brass/aluminum 1050 couple[J].Intermetallics,2011,19(11):1711-1719.
[7]XUE P,NI D,WANG D,XIAO B,MA Z.Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al-Cu joints[J].Materials Science and Engineering A,2011,528(13):4683-4689.
[8]MUTHU M F X,JAYABALAN V.Tool travel speed effects on the microstructure of friction stir welded aluminum–copper joints[J].Journal of Materials Processing Technology,2015,217:105-113.
[9]AKINLABI E T,ELS-BOTES A,MCGRATH P J.Effect of travel speed on joint properties of dissimilar metal friction stir welds[C]//Proceedings of 2nd International Conference on Advances in Engineering and Technology(AET).Uganda,2011.
[10]GALV?O I,LOUREIRO A,VERDERA D,GESTO D,RODRIGUES D M.Influence of tool offsetting on the structure and morphology of dissimilar aluminum to copper friction-stir welds[J].Metall and Mat Trans A,2012,43(13):5096-5105.
[11]MEHTA K P,BADHEKA V J.Effects of tilt angle on the properties of dissimilar friction stir welding copper to aluminum[J].Materials and Manufacturing Processes,2016,31(3):255-263.
[12]AKINLABI E.Effect of shoulder size on weld properties of dissimilar metal friction stir welds[J].J of Materi Eng and Perform,2012,21(7):1514-1519.
[13]GALV?O I,OLIVEIRA J,LOUREIRO A,RODRIGUES D.Formation and distribution of brittle structures in friction stir welding of aluminium and copper:Influence of shoulder geometry[J].Intermetallics,2012,22:122-128.
[14]MARZBANRAD J,AKBARI M,ASADI P,SAFAEE S.Characterization of the influence of tool pin profile on microstructural and mechanical properties of friction stir welding[J].Metallurgical and Materials Transactions B,2014,45(5):1887-1894.
[15]KUMAR A,RAJU L S.Influence of tool pin profiles on friction stir welding of copper[J].Materials and Manufacturing Processes,2012,27(12):1414-1418.
[16]VIJAY S,MURUGAN N.Influence of tool pin profile on the metallurgical and mechanical properties of friction stir welded Al-10wt.%Ti B 2 metal matrix composite[J].Materials&Design,2010,31(7):3585-3589.
[17]PALANIVEL R,MATHEWS P K,MURUGAN N,DINAHARAN I.Effect of tool rotational speed and pin profile on microstructure and tensile strength of dissimilar friction stir welded AA5083-H111 and AA6351-T6 aluminum alloys[J].Materials&Design,2012,40:7-16.
[18]RAMACHANDRAN K,MURUGAN N,KUMAR S S.Effect of tool axis offset and geometry of tool pin profile on the characteristics of friction stir welded dissimilar joints of aluminum alloy AA5052and HSLA steel[J].Materials Science and Engineering A,2015,639:219-233.
[19]PADMANABAN G,BALASUBRAMANIAN V.Selection of FSW tool pin profile,shoulder diameter and material for joining AZ31B magnesium alloy–An experimental approach[J].Materials&Design,2009,30(7):2647-2656.
[20]CHEN Y,NAKATA K.Effect of tool geometry on microstructure and mechanical properties of friction stir lap welded magnesium alloy and steel[J].Materials&Design,2009,30(9):3913-3919.
[21]AVAL H J.Influences of pin profile on the mechanical and microstructural behaviors in dissimilar friction stir welded AA6082–AA7075 butt Joint[J].Materials&Design,2015,67:413-421.
[22]CHOWDHURY S,CHEN D,BHOLE S,CAO X.Tensile properties of a friction stir welded magnesium alloy:Effect of pin tool thread orientation and weld pitch[J].Materials Science and Engineering A,2010,527(21):6064-6075.
[23]KUMAR K,KAILAS S V,SRIVATSAN T S.Influence of tool geometry in friction stir welding[J].Materials and Manufacturing Processes,2008,23(2):188-194.
[24]SURESHA C,RAJAPRAKASH B,UPADHYA S.A study of the effect of tool pin profiles on tensile strength of welded joints produced using friction stir welding process[J].Materials and Manufacturing Processes,2011,26(9):1111-1116.
[25]ELANGOVAN K,BALASUBRAMANIAN V.Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy[J].Materials Science and Engineering A,2007,459(1):7-18.
[26]ELANGOVAN K,BALASUBRAMANIAN V,VALLIAPPAN M.Effect of tool pin profile and tool rotational speed on mechanical properties of friction stir welded AA6061 aluminium alloy[J].Materials and Manufacturing Processes,2008,23(3):251-260.
[27]ELANGOVAN K,BALASUBRAMANIAN V,VALLIAPPAN M.Influences of tool pin profile and axial force on the formation of friction stir processing zone in AA6061 aluminium alloy[J].Int J Adv Manuf Technol,2008,38(3-4):285-295.
[28]ELANGOVAN K,BALASUBRAMANIAN V.Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy[J].Journal of Materials Processing Technology,2008,200(1):163-175.
[29]ELANGOVAN K,BALASUBRAMANIAN V.Influences of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in AA6061 aluminium alloy[J].Materials&Design,2008,29(2):362-373.
[30]MEHTA K P,BADHEKA V J.Effects of tool pin design on formation of defects in dissimilar friction stir welding[J].Procedia Technology,2016,23:513-518.
[31]MEHTA K,BADHEKA V.Investigations on friction stir welding defects for dissimilar copper to aluminum materials under different process parameters[C]//Proceedings of International Conference on Friction Based Processes.IISc-Bangalore,India,2014.
[32]NANDAN R,DEBROY T,BHADESHIA H.Recent advances in friction-stir welding–process,weldment structure and properties[J].Progress in Materials Science,2008,53(6):980-1023.
[33]BAREKATAIN H,KAZEMINEZHAD M,KOKABI A.Microstructure and mechanical properties in dissimilar butt friction stir welding of severely plastic deformed aluminum AA 1050 and commercially pure copper sheets[J].Journal of Materials Science&Technology,2014,30(8):826-834.
[34]BEYGI R,KAZEMINEZHAD M,KOKABI A.Microstructural evolution and fracture behavior of friction-stir-welded Al-Cu laminated composites[J].Metall and Mat Trans A,2014,45(1):361-370.
[35]BHATTACHARYA T K,DAS H,PAL T K.Influence of welding parameters on material flow,mechanical property and intermetallic characterization of friction stir welded AA6063 to HCP copper dissimilar butt joint without offset[J].Transactions of Nonferrous Metals Society of China,2015,25:2833-2846.
[36]MEHTA K P,BADHEKA V J.Experimental investigation of process parameters on defects generation in copper to AA6061-T651 friction stir welding[J].International Journal of Advances in Mechanical&Automobile Engineering,2016,3(1):55-58.
[2]MEHTA K P,BADHEKA V J.Influence of tool design and process parameters on dissimilar friction stir welding of copper to AA6061-T651 joints[J].Int J Adv Manuf Technol,2015,80(9):2073-2082.
[3]MISHRA R S,MA Z.Friction stir welding and processing[J].Materials Science and Engineering:R:Reports,2005,50(1):1-78.
[4]LOHWASSER D,CHEN Z.Friction stir welding:From basics to applications[M].Elsevier,2009.
[5]RAI R,DE A,BHADESHIA H,DEBROY T.Review:Friction stir welding tools[J].Science and Technology of Welding and Joining,2011,16(4):325-342.
[6]ESMAEILI A,RAJANI H Z,SHARBATI M,GIVI M B,SHAMANIAN M.The role of rotation speed on intermetallic compounds formation and mechanical behavior of friction stir welded brass/aluminum 1050 couple[J].Intermetallics,2011,19(11):1711-1719.
[7]XUE P,NI D,WANG D,XIAO B,MA Z.Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al-Cu joints[J].Materials Science and Engineering A,2011,528(13):4683-4689.
[8]MUTHU M F X,JAYABALAN V.Tool travel speed effects on the microstructure of friction stir welded aluminum–copper joints[J].Journal of Materials Processing Technology,2015,217:105-113.
[9]AKINLABI E T,ELS-BOTES A,MCGRATH P J.Effect of travel speed on joint properties of dissimilar metal friction stir welds[C]//Proceedings of 2nd International Conference on Advances in Engineering and Technology(AET).Uganda,2011.
[10]GALV?O I,LOUREIRO A,VERDERA D,GESTO D,RODRIGUES D M.Influence of tool offsetting on the structure and morphology of dissimilar aluminum to copper friction-stir welds[J].Metall and Mat Trans A,2012,43(13):5096-5105.
[11]MEHTA K P,BADHEKA V J.Effects of tilt angle on the properties of dissimilar friction stir welding copper to aluminum[J].Materials and Manufacturing Processes,2016,31(3):255-263.
[12]AKINLABI E.Effect of shoulder size on weld properties of dissimilar metal friction stir welds[J].J of Materi Eng and Perform,2012,21(7):1514-1519.
[13]GALV?O I,OLIVEIRA J,LOUREIRO A,RODRIGUES D.Formation and distribution of brittle structures in friction stir welding of aluminium and copper:Influence of shoulder geometry[J].Intermetallics,2012,22:122-128.
[14]MARZBANRAD J,AKBARI M,ASADI P,SAFAEE S.Characterization of the influence of tool pin profile on microstructural and mechanical properties of friction stir welding[J].Metallurgical and Materials Transactions B,2014,45(5):1887-1894.
[15]KUMAR A,RAJU L S.Influence of tool pin profiles on friction stir welding of copper[J].Materials and Manufacturing Processes,2012,27(12):1414-1418.
[16]VIJAY S,MURUGAN N.Influence of tool pin profile on the metallurgical and mechanical properties of friction stir welded Al-10wt.%Ti B 2 metal matrix composite[J].Materials&Design,2010,31(7):3585-3589.
[17]PALANIVEL R,MATHEWS P K,MURUGAN N,DINAHARAN I.Effect of tool rotational speed and pin profile on microstructure and tensile strength of dissimilar friction stir welded AA5083-H111 and AA6351-T6 aluminum alloys[J].Materials&Design,2012,40:7-16.
[18]RAMACHANDRAN K,MURUGAN N,KUMAR S S.Effect of tool axis offset and geometry of tool pin profile on the characteristics of friction stir welded dissimilar joints of aluminum alloy AA5052and HSLA steel[J].Materials Science and Engineering A,2015,639:219-233.
[19]PADMANABAN G,BALASUBRAMANIAN V.Selection of FSW tool pin profile,shoulder diameter and material for joining AZ31B magnesium alloy–An experimental approach[J].Materials&Design,2009,30(7):2647-2656.
[20]CHEN Y,NAKATA K.Effect of tool geometry on microstructure and mechanical properties of friction stir lap welded magnesium alloy and steel[J].Materials&Design,2009,30(9):3913-3919.
[21]AVAL H J.Influences of pin profile on the mechanical and microstructural behaviors in dissimilar friction stir welded AA6082–AA7075 butt Joint[J].Materials&Design,2015,67:413-421.
[22]CHOWDHURY S,CHEN D,BHOLE S,CAO X.Tensile properties of a friction stir welded magnesium alloy:Effect of pin tool thread orientation and weld pitch[J].Materials Science and Engineering A,2010,527(21):6064-6075.
[23]KUMAR K,KAILAS S V,SRIVATSAN T S.Influence of tool geometry in friction stir welding[J].Materials and Manufacturing Processes,2008,23(2):188-194.
[24]SURESHA C,RAJAPRAKASH B,UPADHYA S.A study of the effect of tool pin profiles on tensile strength of welded joints produced using friction stir welding process[J].Materials and Manufacturing Processes,2011,26(9):1111-1116.
[25]ELANGOVAN K,BALASUBRAMANIAN V.Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy[J].Materials Science and Engineering A,2007,459(1):7-18.
[26]ELANGOVAN K,BALASUBRAMANIAN V,VALLIAPPAN M.Effect of tool pin profile and tool rotational speed on mechanical properties of friction stir welded AA6061 aluminium alloy[J].Materials and Manufacturing Processes,2008,23(3):251-260.
[27]ELANGOVAN K,BALASUBRAMANIAN V,VALLIAPPAN M.Influences of tool pin profile and axial force on the formation of friction stir processing zone in AA6061 aluminium alloy[J].Int J Adv Manuf Technol,2008,38(3-4):285-295.
[28]ELANGOVAN K,BALASUBRAMANIAN V.Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy[J].Journal of Materials Processing Technology,2008,200(1):163-175.
[29]ELANGOVAN K,BALASUBRAMANIAN V.Influences of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in AA6061 aluminium alloy[J].Materials&Design,2008,29(2):362-373.
[30]MEHTA K P,BADHEKA V J.Effects of tool pin design on formation of defects in dissimilar friction stir welding[J].Procedia Technology,2016,23:513-518.
[31]MEHTA K,BADHEKA V.Investigations on friction stir welding defects for dissimilar copper to aluminum materials under different process parameters[C]//Proceedings of International Conference on Friction Based Processes.IISc-Bangalore,India,2014.
[32]NANDAN R,DEBROY T,BHADESHIA H.Recent advances in friction-stir welding–process,weldment structure and properties[J].Progress in Materials Science,2008,53(6):980-1023.
[33]BAREKATAIN H,KAZEMINEZHAD M,KOKABI A.Microstructure and mechanical properties in dissimilar butt friction stir welding of severely plastic deformed aluminum AA 1050 and commercially pure copper sheets[J].Journal of Materials Science&Technology,2014,30(8):826-834.
[34]BEYGI R,KAZEMINEZHAD M,KOKABI A.Microstructural evolution and fracture behavior of friction-stir-welded Al-Cu laminated composites[J].Metall and Mat Trans A,2014,45(1):361-370.
[35]BHATTACHARYA T K,DAS H,PAL T K.Influence of welding parameters on material flow,mechanical property and intermetallic characterization of friction stir welded AA6063 to HCP copper dissimilar butt joint without offset[J].Transactions of Nonferrous Metals Society of China,2015,25:2833-2846.
[36]MEHTA K P,BADHEKA V J.Experimental investigation of process parameters on defects generation in copper to AA6061-T651 friction stir welding[J].International Journal of Advances in Mechanical&Automobile Engineering,2016,3(1):55-58.
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