M.

Ekaditya Albar Rangga Agung Rhidiyan Waroko Rudiyansah

1106154305 1106108942 0806331935 0806331973

Master Degree Program Metallurgy and Material Engineering Department Universitas Indonesia
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Outline
Dissimilar Metal Welding
Journal Review
Enhanced mechanical properties of friction stir welded dissimilar AlCu joint by intermetallic compounds Dissimilar friction welding of induction surface-hardened steels and thermochemically treated steels Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy

Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding

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Dissimilar Metal Welding

The joining of dissimilar materials is becoming increasingly important in industrial applications due to their numerous advantages. These include not only technical advantages, such as desired product properties, but also benets in terms of production economics.
Dissimilar metals are difcult to join with conventional fusion welding due to their different chemical and physical characteristics, thus solid state joining methods have received much attention.

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Journal 1:
Enhanced mechanical properties of friction stir welded dissimilar AlCu joint by intermetallic compounds (May 2010)
Introduction: FSW has been shown to be an effective way of joining materials with poor fusion weldability, such as high-strength aluminum alloys and magnesium alloys. In Al-Cu joints, an intermetallic compound (IMC) layer usually formed on the AlCu interface. IMCs were easily formed in the nugget zone due to severe plastic deformation and thermal exposure. IMCs have been used as reinforcing particles in metal matrix composites (MMCs). Control of the IMC layer between dissimilar metals and the size and distribution of the IMC particles in the nugget zone becomes a key factor for FSW of dissimilar metals. Experiment: 1060 Aluminum + Pure Copper (99.9%) Plate (p x l x t : 300 x 70 x 5 mm) FSW machine (China FSW Center) Tool traverse speed : 100 mm min1 ; Rotation rate : 600 rpm Microstructural Analysis : EPMA, XRD, SEM, TEM, EDS Mechanical Testing : Tensile Test, Vickers Microhardness, Three-point Bending Test Results and Discussions: The nugget zone consists of a mixture of the aluminum matrix and Cu particles. A continuous and uniform interface layer is formed with a thickness of 1 m. Reinforcing particles were mainly composed of Al2Cu, Al4Cu9, and few AlCu particles. UTS of the composite structure was as high as 210 MPa. The hardness increased substantially due to the strengthening effect of the AlCu IMC particles.
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Journal 1:
Enhanced mechanical properties of friction stir welded dissimilar AlCu joint by intermetallic compounds (May 2010)
XRD Result SEM Result

EPMA Result PRZ

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Journal 1:
Enhanced mechanical properties of friction stir welded dissimilar AlCu joint by intermetallic compounds (May 2010)
Hardness Vickers

TEM Result

Tensile Test

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Journal 1:
Enhanced mechanical properties of friction stir welded dissimilar AlCu joint by intermetallic compounds (May 2010)
Bending Test

Conclusions: 1060 aluminum alloy and commercial pure copper were successfully friction stir welded. Reinforcing particles were mainly composed of Al2Cu, Al4Cu9, and few AlCu particles. UTS of the composite structure was as high as 210 MPa. The hardness increased substantially due to the strengthening effect of the AlCu IMC particles. Bending without fracture was generated at the AlCu interface.
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Journal 2:
Dissimilar friction welding of induction surface-hardened steels and thermochemically treated steels (April 2012)
Background: Friction welding is a highly productive process that relies on the conversion of mechanical energy into thermal energy. For friction joining of surface hardened steels, the distribution of the thermal gradient on the surfaces in contact during the process is affecting the hardness at the interface. This work is focused on the particularities of the conventional friction welding process of dissimilar steels for joints in which one component is induction-hardened, using high frequency currents, and the other one is subject to another heat or thermochemical treatment, such as carburization or nitriding.

Experiment: Hardness test (HVS 10A1 hardness tester on longitudinal section, polished and nital-etch join) Macroscopic (Olympus SZH-10 stereo microscope) Microstructure (Olympus BH-2 metallographic microscope) Bending test (Instron 250 kN universal testing machine) Torsion test (Schenk-Trebel torsion testing machine 1600Nm) Impact test (V-Notched, 300 J Charpy pendulum)

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Journal 2:
Dissimilar friction welding of induction surface-hardened steels and thermochemically treated steels (April 2012)

Materials
Steel C45 C55 16MnCr5 34CrNiMo6 C 0.48 0.56 0.17 0.36 Mn 0.63 0.61 1.14 0.61 Si 0.25 0.27 0.31 0.28 P 0.029 0.028 0.025 0.027 S 0.028 0.024 0.026 0.027 Cr 1.07 1.52 Mo 0.24 Ni 1.54

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Journal 2:
Dissimilar friction welding of induction surface-hardened steels and thermochemically treated steels (April 2012)
Treatments

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Fig. 1. Hardness gradient of the C55 steel after high frequency inductionhardening

Fig. 2. Macro and micrographic images of the dissimilar C55 inductionhardened with a C45 quench-hardened steel friction welded joint

Fig. 3. Hardness gradients for two values of the friction/upsetting pressure across the joining plane for the dissimilar C45 quench-hardened-C55 induction-hardened friction welded joint, measured in the marginal and central areas, respectively
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Fig. 4. Details about the microstructure and hardness gradients in pre-welding state for the 16MnCr5 (carburized) and 34CrNiMo6 (induction-hardened) steels used in the experiments.

Fig. 5. Macro and microscopic images of the friction welded joints of induction-hardened 34CrNiMo6 and 16MnCr5 carburized-quenched-tempered steels.

Fig. 6. Hardness gradients in axial direction across the joint plane for the induction-hardened 34CrNiMo6 steel with a 16MnCr5 carburizedquenched-tempered steel joint for two values of the friction/forging pressure.
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Fig. 7. Typical microstructure and hardness gradient observed for the C45 after the nitriding operation and the macroscopic image of the C55 inductionhardened and C45 nitrided steel joint.

Results and Discussions: A biconcave HAZ forms for high friction/forging pressures (300/400 N/mm2), if one of the components is thermomechanically treated. The decrease of the pressure did not affect the process, neither the extent of the softening area. The nitride layer contributes to the reduction of the relative friction between the components in the vicinity of the rotational axis. The experimental results show that a high quality joint can only be obtained if the nitride layer is fully expunged from the joint plane. If such nitride debris are still present, a quasi-cleavage fracture occurs due to the high cooling rate during the friction welding process, as also observed for other combinations with nitrided steels.

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Journal 2:
Dissimilar friction welding of induction surface-hardened steels and thermochemically treated steels (April 2012)
Conclusions: The friction pressure is limited to about 200 N/mm2, since higher values were observed to lead only to minor reduction of the hardness on the inductionhardened surface and can favor the presence of discontinuities in the center of the joint plane. Influenced by the presence hard layers in the join plane. By increasing the axial pressure, the thermochemically hardened layer can be expunged in the burr. The presence of the nitride layer contributes to the reduction of the friction in the vicinity of the rotational axis. Regardless of the friction/forging pressures used (200/300 or 300/400 N/mm2) the joints showed good mechanical properties, but the complete expulsion of the nitride layer was observed only for 6 mm upset length.

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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Background: Al alloy (combination between mass reduction and high strength); Mg alloy (low density and high specific strength). Joining Al alloy and Mg alloy will be difficult if we use conventional fusion welding because of large intermetallic compounds. FSW is a potential candidate for dissimilar welding because of lower processing temperature and can produced defect-free weld, i.e. joining Al 2024/Al 7075, Al/steel, Al/Cu, dan Al/Mg Experiment: 5052 Al alloy + AZ31 Mg alloy, plate thickness 6 mm. Surface of plate was grounded using grit paper to remove oxide layer then cleaned by ethanol. 5052 Al alloy (advancing side) and AZ31 Mg alloy (retreating side) from tool pin in FSW process. FSW machine using FSW-3LM-003, vrot = 600 r/min and vwelding = 40 mm/min. Butt join was resulted parallel to rolling path direction. Microstructure analysis at cross section of weld direction by OM (KEYENCE VHX-600) and SEM (Quata200) Etch solution: picric acid (4,2 g), acetic acid (8 ml), distilled water (10 ml), ethanol (70 ml). Hardness measurement by HVS-100 digit hardness tester, load ! N, dwell time 20 sec.

Materials

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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Defect-free using FSW (vrot = 600 r/min, vwelding = 40 mm/min).
Interface Mg alloy + Al alloy

Fig. 1. Surface appearance of dissimilar weld prepared by FSW

Defect-free

Fig. 2. Optical approach of cross-section of dissimilar weld

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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Simple bond interface Intermixed structure

Fig. 2. Optical approach of cross-section of dissimilar weld

In Fig. 2 we can see typical microstructural zone, like Base Material (BM), Heat-Affected Zone (HAZ), Thermomechanical Affected Zone (TMAZ), and Stir-Zone (SZ).

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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of crosssection of dissimilar weld

Fig. 3. SEM images of AZ31 in different regions, marked with letters in Fig.2:

(a) BM;
(b) (c) (d) (e) (f) HAZ; Interface of TMAZ/SZ; SZ in Mg side; SZ in Al side; Intercalated microstructure.

BM terdiri dari large equiaxed grains (50 m) dan fine grains (10 m).
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld

Fig. 3. SEM images of AZ31 in different regions, marked with letters in Fig.2:

(a)
(c) (d) (e) (f)

BM;
Interface of TMAZ/SZ; SZ in Mg side; SZ in Al side; Intercalated microstructure.

(b) HAZ;

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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld

Fig. 3. SEM images of AZ31 in different regions, marked with letters in Fig.2:

(a)
(b)
(d) (e) (f)

BM;
HAZ;
SZ in Mg side; SZ in Al side; Intercalated microstructure.

(c) Interface of TMAZ/SZ;

Dynamic rekristalisasi terjadi di SZ dikarenakan deformasi plastis dan efek termal siklik yang disebabkan rotational tool.
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld

Fine equiaxed rekristalisasi grains menghasilkan struktur yang berbeda pada lokasi yang berbeda dari SZ, seperti pada daerah d, e, f. (Fig. 2) Fig. 3. SEM images of AZ31 in different regions, marked with letters in Fig.2:

(a)
(b) (c)
(e) (f)

BM;
HAZ; Interface of TMAZ/SZ;
SZ in Al side; Intercalated microstructure.

(d) SZ in Mg side;

Grain dengan ukuran rata-rata 5,4 m (daerah d / sisi Mg) dimana lebih kecil dibandingkan BM.
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld

Fine equiaxed rekristalisasi grains menghasilkan struktur yang berbeda pada lokasi yang berbeda dari SZ, seperti pada daerah d, e, f. (Fig. 2) Fig. 3. SEM images of AZ31 in different regions, marked with letters in Fig.2:

(a)
(b) (c) (d)
(f)

BM;
HAZ; Interface of TMAZ/SZ; SZ in Mg side;
Intercalated microstructure.

(e) SZ in Al side;
Grain dengan ukuran rata-rata 6,9 m (daerah d / sisi Al) dimana lebih kecil dibandingkan BM.
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld

Fine equiaxed rekristalisasi grains menghasilkan struktur yang berbeda pada lokasi yang berbeda dari SZ, seperti pada daerah d, e, f. (Fig. 2)
Fig. 3. SEM images of AZ31 in different regions, marked with letters in Fig.2:

(a)
(b) (c) (d) (e)

BM;
HAZ; Interface of TMAZ/SZ; SZ in Mg side; SZ in Al side;

(f)

Intercalated microstructure.

Struktur interkalasi terbentuk dan ukuran grains rata-rata dari AZ31 Mg alloy (2,8 m)
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld Hal menarik dapat diamati pada daerah g (Fig. 2) dimana berlokasi di SZ dekat sisi 5052 Al alloy dan dikelilingi oleh Mg alloy.

Fig. 4. Microstructures of onion ring in dissimilar weld:

(a) Optical microstructure;

(b) (c) (d) EDS maps of Mg; EDS maps of Al; Distribution in onion ring.

Fig. 4 (a) menunjukkan mikrostruktur terdiri dari dua pita dengan beda kontras. Menurut hasil analisis EDX, pita gelap (Mg) dan pita putih (Al), dimana mirip onion ring, namun bentuknya berbeda dari monolitik FSW.
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld Hal menarik dapat diamati pada daerah g (Fig. 2) dimana berlokasi di SZ dekat sisi 5052 Al alloy dan dikelilingi oleh Mg alloy.

Fig. 4. Microstructures of onion ring in dissimilar weld:

(a)
(c) (d)

Optical microstructure;
EDS maps of Al; Distribution in onion ring.

(b) EDS maps of Mg;

Fig. 4 (b) menunjukkan peta EDX dari distribusi Mg pada daerah g.

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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld Hal menarik dapat diamati pada daerah g (Fig. 2) dimana berlokasi di SZ dekat sisi 5052 Al alloy dan dikelilingi oleh Mg alloy.

Fig. 4. Microstructures of onion ring in dissimilar weld:

(a)
(b) (d)

Optical microstructure;
EDS maps of Mg; Distribution in onion ring.

(c) EDS maps of Al;

Fig. 4 (c) menunjukkan peta EDX dari distribusi Al pada daerah g.

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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Fig. 2. Optical approach of cross-section of dissimilar weld Hal menarik dapat diamati pada daerah g (Fig. 2) dimana berlokasi di SZ dekat sisi 5052 Al alloy dan dikelilingi oleh Mg alloy.

Fig. 4. Microstructures of onion ring in dissimilar weld:

(a)
(b) (c)

Optical microstructure;
EDS maps of Mg; EDS maps of Al;

(d) Distribution in onion ring.

Komposisi kimia : 83% Al + 17 % Mg (mass fraction), dimana struktur lamella merupakan komposisi dari pita Al + Mg.
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Distribution of Microstructure
o Nilai Vickers microhardness dari dissimilar weld diukur sepanjang garis yang ditandai pada Fig. 2 dimana posisinya 1,5 mm (atas), 3 mm (tengah), 4,5 mm (bawah) dari permukaan atas. o Hasilnya Fig. 5

Fig. 2 .Optical approach of cross-section of dissimilar weld

Microhardness menunjukkan distribusi tidak seragam. Hardness SZ > BM. Nilai maksimum hardness: posisi tengah SZ dimana 2x lebih besar dari BM. Struktur onion-ring dan mikrostruktur interkalasi penyebab variasi tajam hardness di weld zone.
Fig. 5. Microhardness profiles of microstructure from Mg to Al with different locations
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)
Tensile Testing
Fig. 6. Fracture section of AZ31/5052 dissimilar friction stir weld: (a) Tensile fracture location; (b) SEM image of fracture surface

Fig. 6 menunjukkan lokasi patah tarik dan morfologi patahan dari dissimilar weld yang diuji tegak lurus dari arah welding. Spesimen uji tarik gagal pada lokasi 2,5 mm dari pusat sambungan pada sisi advancing. Fig. 6 (a) Pada lokasi ini, gradien hardness merupakan yang paling tajam, menurut Fig. 5. Fig. 6 (b) menunjukkan morfologi patahan SEM yang diamati dari arah normal terhadap permukaan patahan. Bentuk cleavage-like dapat ditemukan pada permukaan patahan (patah brittle).
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Journal 3:
Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy (January 2010)

Conclusions: Sound weld 5052 Al alloy + AZ31 Mg alloy dapat dihasilkan melalui FSW dengan vrot = 600 r/min dan vwelding = 40 mm/min. Mikrostruktur BM menjadi bentuk equiaxed dan fine grains pada SZ. Dimana pada bagian atas SZ, 5052 + AZ31 alloy simply bonded, sedangkan struktur onion-ring (komposisi pita Al + Mg) terbentuk di bagian bawah SZ. Profil microhardness menunjukkan distribusi tidak seragam, dengan nilai maksimum microhardness SZ dua kali lebih besar dibandingkan BM. Posisi patahan berada pada jarak 2,5 mm dari pusat sambungan (pada sisi Al), dimana gradien hardness merupakan yang paling tajam.

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Journal 4:
Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding (October 2009)
Background: Lap joints of 1060 aluminum alloy and commercially pure copper by FSW Usually a large void formation, cracks and other distinct defects throughout the weld Mechanically mixed region in weld nugget consisting Mainly CuAl2, CuAl, and Cu9Al4, brittle nature of the Inter Metallic Compound (IMC) The effect of welding speed on interface morphology (lap joint conguration), microstructure, and joint strength Lowering the amount of heat in interface may result in limited formation of IMC

Experiment: Rolled plates of 1060 aluminum alloy (top) and commercially pure copper (bottom) in lap joint Dimension of sample 20 mm length and 10 mm width and before welding, the samples were degreased using acetone Make lap joints, a FSW adapted milling machine was used The couple samples were friction stir welded with the pin rotating clockwise at speed of 1180 rpm and welding speeds of 30, 60, 95, 118, 190, 300, and 375 mm/min Microstructural analysis : Metallographic analysis (OM + SEM + EDS) Mechanical testing : Tensile Shear Test

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Journal 4:
Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding (October 2009)
Results and Discussions: Extremely high welding speeds in the present work (300 and 375 mm/min), produced very poor metallic bonding (higher welding speed caused less vertical transport of interface). The interface in the central region has moved considerably into the bottom plate. This vertical transport of interface is attributed to the ring-vortex ow of materials created by pin threads. In the aluminum close to the Al/Cu interface, a dark area was observed (higher welding speeds, this are a was limited to a narrower region and extended toward the advancing side of the joints). Cavity defects which are formed outside the optimum FSW conditions, caused by an insufcient heat input (with increasing the welding speed, this type of defect is more likely to occur). As a matter of fact, decreasing the welding speed gives effective inuence on the plastic ow and consequently increasing the heat input). Lowering the amount of heat in interface may result in limited formation of IMC.

Macroscopic overviews of the FSW joint cross sections at constant tool rotational speed of 1180 rpm and welding speeds of (a)30, (b)60, (c)95, (d)118, and (e)190mm/min

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Journal 4:
Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding (October 2009)
Results and Discussions: The microstructure of the aluminum stir zone was characterized by the equiaxed ne grains (that the equiaxed ne grains were formed through the dynamic recrystallization during FSW) The TMAZ area characterized by elongated grains and layers which is between stir zone and the HAZ areas Copper particles with irregular shape and inhomogeneous distribution were observed in the aluminum dark area (copper plate near interface was unable to sustain very large vertical elongation and tore apart into the small-elongated particles that were found in various places in the dark area)

Microstructures showing different regions of (a) ne equiaxed grains in stir zone of aluminum near Al/Cu interface,(b) elongated aluminum grains in the TMAZ of advancing side
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Journal 4:
Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding (October 2009)

SEM image of copper particle surrounded by equiaxed grains of Al 1060 Alloy in the weld nugget for the joint produced by rotational speed of 1180 rpm and welding speed of 90 mm/min

The back scattered electron (BSE) image of a coarse particle existing in the nugget shows as tacked layer structure inside; the EDS spectra for positions A (light gray layers), B (dark gray layers), C (white layers) shows possible existence of Al4Cu9, Al2Cu, and base copper, respectively (welding condition: 95mm/min, 1180rpm)

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Journal 4:
Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding (October 2009)

The failure loads ranged from 1902 to 2642 N. One can nd that with increasing the welding speed, failure load increases up to a maximum value and then decreasing behavior is appeared. The shear load of the joint is probably affected by two factors: the amount of microcracks, and cavity formation.

General tensile fracture surface of a specimen friction stir welded at rotational and welding speed of 1180 rpm and 95 mm/min, respectively. The fracture occurred at the advancing side of aluminum plate containing copper fragments (white colored particles)
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Journal 4:
Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding (October 2009)

Conclusions: The maximum tensile shear strength has been achieved at welding speed of 95 mm/min Due to formation of high amount of micro cracks in the dark area at welding speeds of 30 and 60 mm/min, the tolerable tensile shear was lower than that of 95 mm/min Higher welding speeds of 118 and 190 mm/min, the cavity defects are produced and again tensile shear strength is decreased in compare with 95 mm/min Lower welding speed caused more vertical transport, while a higher welding speed caused less vertical transport on the retreating side

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References
Ion Mitelea, Victor Budau, Corneliu Craciunescu. Dissimilar friction welding of induction surface-hardened steels and thermochemically treated steels. Journal of Materials Processing Technology 212 (2012) 18921899.
P. Xue, B.L. Xiao, D.R. Ni, Z.Y. Ma. Enhanced mechanical properties of friction stir welded dissimilar AlCu joint by intermetallic compounds. Materials Science and Engineering A 527 (2010) 57235727. T. Saeid, A. Abdollah-zadeh, B.Sazgari. Weldability and mechanical properties of dissimilar aluminumcopper lap joints made by friction stir welding. Journal of Alloys and Compounds 490 (2010) 652655. Yan Yong, Zhang Da-tong, Qiu Cheng, Zhang Wen. Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy. Trans. Nonferrous Met. Soc. China 20 (2010) s619-s623.

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