TWI

Dissimilar butt and lap joints between AA 5083-H111 or AA 6082-T6 aluminium alloys and copper were fabricated by friction stir welding and morphological, metallographic and structural analyses were undertaken on weldments made under a range of process conditions. Cu/5083-H111 joints were butt welded in an ESAB LEGIO 3U machine using welding tools with different shoulder geometries at a traverse speed of 160 mm/min and a tool rotational speed of 750 or 1000 rpm. Dissimilar Cu-Al lap welds were fabricated with both aluminium alloys in an MTS I-Stir PDS machine using a conical tool at a traverse speed of 50 mm/min and a rotational speed of 600 rpm. Joint microstructures and weld surfaces were observed by optical microscopy, SEM and micro X-ray diffraction. Issues discussed include the effects of parent material positioning, process parameters and tool geometry on weld structure and morphology, intermetallic phase content of the weld nugget, and the different mechanical properties of 5083 and 6082 aluminium alloys.

9th International Symposium, 15-17 May 2012, Poster Session, Paper 04