Effect of Pre-set Welding Wire on Microstructure and Mechanical Properties of Al/Cu Dissimilar FSW T-Lap Joints
It is difficult to achieve Al/Cu dissimilar welds with good mechanical properties for T-lap joints,due to the low heat input and poor plastic flow of the inner comer of the T-joint in friction stir welding(FSW),which leads to easy occurrence of wormholes,tunnel,bonding line defects,etc,and thus further causes stress concentration.Therefore,pre-set welding wires at the fillet were innovatively applied to 6061-T6 aluminum alloy(4 mm in thickness)and pure copper dissimilar plate FSW T-lap joints,in order to improve the internal plastic flow of T-joints,reduce defects,and obtain joints with good microstructure and properties.The effect of three types of pre-set wires on the microstructure and mechanical properties of Al/Cu dissimilar FSW T-lap joints was analyzed.Results reveal that three types of pre-set wire joints exhibit onion ring-like pattern in the large pin stirring zone at a constant travel speed of 35 mm/min and a rotation speed of 700-800 r/min.The progressive tool at all rotation speeds effectively inhibits migration of large amounts of stringer material to the skin and avoids base materials mixing.Small amounts of Cu particles are mechanically stirred and have a long flow path in the large pin stirring regions,which inhibits the formation of brittle Al/Cu intermetallic compound(IMC)phases during welding.Al/Cu forms effective metallurgical bonding,and the IMC thickness of the Al/Cu interface is less than 1 μm.The Al/Cu T-joints with pre-set Cu are similar to butt joints of the same material in the skin direction,showing a typical ductile fracture.In Al/Cu T-joints with pre-set Al,the direction of the bonding line defects is changed,a certain height of Al/Cu mixing zone is obtained in the direction of the stringer,achieving optimal mechanical interlocking bonding,and break mostly occurs at the intersection,with a tensile strength of 157 MPa,showing hybrid fracture.The pre-set welding wire is proved to be a good method for Al/Cu dissimilar FSW T-lap joints.
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