Microstructure and fracture behavior of friction stir lap welding of dissimilar aa 6060-t5/ pure copper

This study aims to understand the uncertainty about the optimum or best pin position (Dp) for friction stir lap welding (FSLW) of Al-Cu. Tensile shear testing is used to determine the Mechanical strength of FSL welds under static loading. Fracture strength (σLap) corresponding to the maximum load in a test over the sample width is used as the strength value. Interface microstructures differ depending on whether the tool pin penetrates the lapping interface. It has been found that σLap values of the defect free weld samples vary quite significantly and in general are significantly higher than those reported in the literature. When the pin penetration is close to zero no intermetallic layers were formed, hence the value of σLap was zero. When the pin penetration is 0.4mm, the commonly observed a thin Al–Cu interface layer forms and this layer does not grow beyond 3µm. It is shown that the thin interfacial layer can withstand a high tensile-shear load and thus the adjacent Al material shears to fracture. When the pin penetrates more than 0.4mm, the commonly observed mix stir zone (MSZ) forms and values of σLap are lower than that of 0.4mm pin penetration welds but remain quite high.