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Effect of friction spot welding parameters on the joint formation and mechanical properties of Al to Cu

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Abstract

Friction spot welding is an appealing technique for joining dissimilar materials, such as aluminum and copper that have significant differences in physical and mechanical properties. To optimize the welding process, a full-factorial design was employed. It is found that in addition to the plunge depth, the interaction between the rotational speed and the plunge depth significantly influences the lap-shear strength of the Al/Cu dissimilar joints. Further investigations on macro- and microstructures show that increasing the plunge depth could deform the Cu sheet into a concave shape to form a mechanical interlocking, and thus increase the joint lap-shear strength; increasing the tool rotational speed, however, may compromise this effect because of the formed tunnel defects on the interface due to high thermal exposure.

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Authors and Affiliations

  1. Department of Materials Engineering (DEMa), Federal University of Sao Carlos (UFSCar), Rodovia Washington Luiz—km 235, São Carlos, SP, 13565-905, Brazil

    Maria E. B. Cardillo, Nelson G. de Alcântara & Conrado R. M. Afonso

  2. Institute of Materials Research, Materials Mechanics, Solid State Joining Processes (WMP), Helmholtz-Zentrum Geesthacht GmbH, Max-Planck-St. 1, 21502, Geesthacht, Germany

    Junjun Shen & Jorge F. dos Santos

Authors
  1. Maria E. B. Cardillo
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  2. Junjun Shen
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  3. Nelson G. de Alcântara
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  4. Conrado R. M. Afonso
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  5. Jorge F. dos Santos
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Corresponding author

Correspondence to Junjun Shen.

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Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

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Cardillo, M.E.B., Shen, J., de Alcântara, N.G. et al. Effect of friction spot welding parameters on the joint formation and mechanical properties of Al to Cu. Weld World 63, 33–41 (2019). https://doi.org/10.1007/s40194-018-0632-4

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  • DOI: https://doi.org/10.1007/s40194-018-0632-4

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