Transactions of Nonferrous Metals Society of China The Chinese Journal of Nonferrous Metals

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中国有色金属学报(英文版)

Transactions of Nonferrous Metals Society of China

Vol. 31    No. 12    December 2021

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Theoretical and experimental studies on fabrication of two-layer aluminum-copper pipe by friction stir additive manufacturing
Mehdi FALAHATI NAQIBI1, Majid ELYASI1, Hamed JAMSHIDI AVAL2, Mohammad Javad MIRNIA1

1. Department of Mechanical Engineering, Babol Noshirvani University of Technology, Shariati Avenue, Babol 47148-71167, Iran;
2. Department of Materials Engineering, Babol Noshirvani University of Technology, Shariati Avenue, Babol 47148-71167, Iran

Abstract:Using a friction stir additive manufacturing (FSAM) process, the fabrication of a two-layer aluminum- copper pipe was studied experimentally and numerically. For this purpose, by presenting a 3D thermo-mechanical model in ABAQUS software, the temperature and strain distributions during the process were studied. The simulation results show that, although the rotational-to-traverse speed ratio with a good approximation can predict the heat input during welding, it is not a precise measure to predict the occurrence of defects in the weld cross-section. There is a good agreement between the predicted and experimental thermal results, and the maximum relative error is 4.1% in estimating the maximum temperature during welding. Due to heat and severe plastic deformation in the stir zone, the aluminum-copper intermetallic compounds (CuAl2 and Cu9Al4) are formed. The maximum hardness in the stir zone is 301.4 HV0.1 in sample welded with an overlap of -0.5 mm. The ultimate tensile strength and elongation of the two-layer pipe fabricated by friction stir additive manufacturing are (319.52±2.31) MPa and 19.47%, respectively.

 

Key words: friction stir welding; thermo-mechanical simulation; two-layer Al-Cu pipes; microstructure; mechanical properties

ISSN 1004-0609
CN 43-1238/TG
CODEN: ZYJXFK

ISSN 1003-6326
CN 43-1239/TG
CODEN: TNMCEW

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