Current Trends in Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW) (eBook)

Foreword 6
Preface 8
Acknowledgements 10
Contents 11
1 General Introduction 14
Abstract 14
1.1 Welding Process Overview 14
1.1.1 Gas Welding 15
1.1.2 Resistance Welding 15
1.1.3 High Energy Density Welding 15
1.1.4 Solid-State Welding 17
1.1.4.1 Friction Stir Welding (FSW) 17
1.1.4.2 Friction Stir Spot Welding (FSSW) 17
1.1.4.3 FSW and FSSW Joint Configurations 20
1.1.4.4 FSW and FSSW Tools 20
1.1.4.5 Tool Material 21
1.1.4.6 Areas of Applications of FSW and FSSW 22
1.1.4.7 Current State of FSW and FSSW Between Aluminium and Copper 23
1.2 Conclusions 25
References 25
2 Friction Stir Welding and Friction Stir Spot Welding of Aluminium/Copper Alloys 30
Abstract 30
2.1 Introduction 30
2.2 Solid State Welding 31
2.3 Metallurgy of the Aluminium-Copper System 31
2.4 Friction Stir Welding 32
2.5 Friction Stir Welding Between Aluminium and Copper 33
2.5.1 Microstructure Evolution and Chemical Properties 33
2.5.2 Mechanical and Electrical Properties 54
2.6 Friction Stir Spot Welding Between Aluminium and Copper 65
2.6.1 Process Parameters 68
2.6.2 Microstructural Evolution 70
2.6.3 Mechanical and Electrical Properties 72
2.7 Conclusions 74
References 75
3 Friction Stir Welding and Friction Stir Spot Welding of Similar Aluminium and Copper Alloys 79
Abstract 79
3.1 Introduction 79
3.2 Friction Stir Welding of Similar Aluminium Alloys 80
3.2.1 The Friction Stir Welding of Similar Aluminium 2xxx Series 80
3.2.2 Friction Stir Welding of Similar Aluminium 5xxx Series 91
3.2.3 Friction Stir Welding of Similar Aluminium 6xxx Series 92
3.2.4 Friction Stir Welding of Similar Aluminium 7xxx Series 97
3.3 Friction Stir Spot Welding of Similar Aluminium 99
3.3.1 Friction Stir Spot Welding of Similar Aluminium 2xxx Series 104
3.3.2 Friction Stir Spot Welding of Similar Aluminium 5xxx Series 107
3.3.3 Friction Stir Spot Welding of Similar Aluminium 6xxx Series 110
3.3.4 Friction Stir Spot Welding of Similar Aluminium 7xxx Series 112
3.4 Friction Stir Welding of Similar Copper 114
3.5 Friction Stir Spot Welding of Similar Copper Alloys 125
3.5.1 Microstructural Evolution and Weld Defects 125
3.5.2 Mechanical Properties 126
3.6 Conclusion 129
References 129
4 Microstructure and Chemical Analysis of Friction Stir Spot Welding Between Aluminium and Copper (Case Study) 134
Abstract 134
4.1 Introduction 134
4.2 Experimental Procedure 135
4.3 Results and Discussion 137
4.3.1 Microstructural Evolution 138
4.3.2 Chemical Analysis 146
4.3.2.1 Energy Dispersive Spectroscopy Analyses (EDS) 150
4.4 Conclusion 162
References 162
5 Microhardness Profile and Shear Tensile Test of FSSWelds AA1060 to C11000 (Case Study) 164
Abstract 164
5.1 Introduction 164
5.2 Materials and Methods 165
5.2.1 Vickers Microhardness Profile 165
5.2.2 Shear Tensile Testing 167
5.3 Results and Discussion 167
5.4 Conclusions 185
References 185
6 Residual Stresses in Friction Stir Spot Welded AA1060 to C11000 Using the X-Ray Diffraction Technique (Case Study) 187
Abstract 187
6.1 Introduction 188
6.2 Materials and Methods 192
6.3 Results and Discussion 194
6.3.1 Effect of Process Parameters on the Formation of a Copper Ring (Hook) 194
6.3.2 Residual Stress Analyses Using the XRD Technique 196
6.3.3 Effect of Process Parameters on the FHWM of the Spot Welds 201
6.3.4 Electrical Resistivity Measurements 202
6.4 Conclusions 208
References 209
Glossary 211