final project compiled as requirement to obtain bachelor
TRANSCRIPT
A REVIEW ON DISSIMILAR FRICTION STIR WELDING OF COPPER
TO ALUMINIUM: PROCESS PROPERTIES AND VARIANTS
Final Project
Compiled as Requirement to obtain Bachelor Degree in Mechanical
engineering
Universitas Muhammadiyah of Surakarta
Compiled by
Mr.Saeed Worasutr D200133012
MECHANICAL ENGINEERING DEPARTMENT, FACULTY OF ENGINEERING
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2020
i
APPROVAL PAGE
UNIVERSITAS MUHAMMADIYAH SURAKARTA
FACULTY OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
Name Saeed Worasutr
Student ID D200133012
Title A REVIEW ON DISSIMILAR FRICTION STIR WELDING
OF COPPER TO ALUMINIUM: PROCESS PROPERTIES
AND VARIANTS
Date 26 February 2020
Supervisor
Ir. Agus Dwi Anggono, ST., M.Eng., Ph.D
ii
VALIDATION
The final year project entitles "A REVIEW ON DISSIMILAR FRICTION STIR
WELDING OF COPPER TO ALUMINIUM: PROCESS PROPERTIES AND VARIANTS”
has been approved by supervisors and authorized by the secretary of the international
program as partial fulfilment of the requirements for getting the bachelor degree of
engineering in the mechanical engineering department of Universitas Muhammadiyah of
Surakarta.
Written by:
Name : Mr.Saeed Worasutr
NIM: D200133012
Has Approved and legalized on:
Day: Monday
Date: 13 July 2020 Team
Examiners :
Chair person : Ir. Agus Dwi Anggono, ST., M.Eng., Ph.D
Member 1 : Wijianto, ST.M.Eng.Sc
Member 2 : Muhammad Syukron,S.T, M.Eng.,Ph.D
(Ir. Sri Sunarjono, M.T, Ph.D)
Admitted by,
Head of Department
(...............................)
(..............................)
(...............................)
iii iii
STATEMENT LETTER
PUBLICATION OF SCIENTIFIC WORKS
Bismillahirrahmanirrohim
The undersigned below this, me
Name : Mr.Saeed Worasutr
NIM : D200133012
Faculty/Department : Engineering/Mechanical engineering
Title : A REVIEW ON DISSIMILAR FRICTION STIR WELDING Of
COPPER TO ALUMINIUM: PROCESS PROPERTIES AND
VARIANTS.
Hereby declare that I agree to
1. Give right royalty-free to Library UMS top writing creation scientific I, for the sake of
development science knowledge.
2. Give right store, transfer my provide, manage to inform database, distribute and Display it in
softcopy for Interests academic to Library UMS, without need ask permission from me for
permanent List name I as author/creator.
3. Ready and ensure forbear on personal without involve party UMS Library of all form
Demands law arising on violation right create in creation scientific this.
So this statement I made with the truth and hopefully can be used as it should be.
Surakarta, July 20, 2020
Sincerely
Mr.Saeed Worasutr
4
TINJAUAN TENTANG PENGHASILAN GESEKAN DISSIMILAR DENGAN
TEMBAGA KE ALUMINIUM: PROSES DAN VARIAN PROSES
Abstrak
Friction stir welding (FSW) telah menjadi proses penting dalam penggabungan paduan
aluminium dan bahan lain yang relatif lunak terhadap bahan yang digunakan sebagai alat untuk
mengaduk logam. Berbeda dengan pengelasan gesekan tradisional, yang biasanya dilakukan pada
bagian aksisimetris kecil yang dapat diputar dan didorong satu sama lain untuk membentuk
sambungan. pengelasan gesekan aduk dapat diterapkan untuk berbagai jenis sambungan seperti
sambungan pantat, sambungan putaran, sambungan butt T, dan sambungan fillet.Teknologi
pengelasan gesekan adukan (FSW) layak untuk bergabung dengan material yang berbeda karena
sifatnya yang padat. Artikel saat ini memberikan wawasan yang komprehensif tentang bahan
tembaga ke aluminium yang berbeda yang digabungkan dengan teknologi FSW. Parameter FSW
seperti desain pahat, offset pin pahat, kecepatan rotasi, kecepatan pengelasan, sudut kemiringan
pahat, dan posisi material benda kerja dalam fixture untuk sistem Cu – Al yang berbeda
dirangkum dalam artikel ulasan ini. Selain itu, cacat pengelasan, struktur mikro, dan
pembentukan senyawa intermetalik untuk sistem FSW Cu-Al juga telah dibahas dalam artikel ini.
Selain itu, perkembangan baru dan ruang lingkup masa depan dari sistem Cu Al berbeda telah
ditangani.
Kata Kunci: FSW,Sambungan,Tembaga,Aluminium, , sambungan putaran,pin pahat.
A REVIEW ON DISSIMILAR FRICTION STIR WELDING OF COPPER TO
ALUMINIUM: PROCESS PROPERTIES AND VARIANTS
Abstract
Friction stir welding (FSW) has now become an important process in the joining of aluminium
alloys and other materials which are soft relative to the material used as the tool for stirring the
metal. In contrast to the traditional friction welding, which is usually performed on small
axisymmetric parts that can be rotated and pushed against each other to form a joint. friction stir
welding can be applied to various types of joints like butt joints, lap joints, T butt joints, and fillet
joints.Friction stir welding (FSW) technology is feasible to join dissimilar materials because of its
solid-state nature. The present article provides a comprehensive insight on dissimilar copper to
aluminium materials joined by FSW technology. FSW parameters such as tool design, tool pin
offset, rotational speed, welding speed, tool tilt angle, and position of workpiece material in a
fixture for dissimilar Cu–Al system are summarized in the present review article. Additionally,
welding defects, microstructure, and intermetallic compound generation for Cu–Al FSW system
have been also discussed in this article. Furthermore, the new developments and future scope of
dissimilar Cu–Al FSW system have been addressed.
Keyword: FSW, copper, aluminium, lap joint, Tool pin
1. INTRODUCTION
In this case study, the main point of this research is Friction Stir Welding (FSW) of aluminium to copper.
The Friction Stir welding or FSW is a relatively new solid-state joining process. This joining technique is
energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength
aerospace aluminium alloys and other metallic alloys that are hard to weld by conventional fusion welding.
FSW is considered to be the most significant development in metal joining in a decade.
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Friction stir welding (FSW) technology is feasible to join dissimilar materials because
of its solid-state nature. The present article provides a comprehensive insight on dissimilar
copper to aluminium materials joined by FSW technology. FSW parameters such as tool
design, tool pin offset, rotational speed, welding speed, tool tilt angle, and position of
workpiece material in the fixture for dissimilar Cu–Al system are summarized in the present
review article. Additionally, welding defects, microstructure, and intermetallic compound
generation for Cu–Al FSW system have been also discussed in this article. Furthermore, the
new developments and future scope of dissimilar Cu–Al FSW system have been addressed.
Copper and Aluminium materials are extensively used in difficult industries because
of their great conductivity and corrosion-resistant nature. The joining of dissimilar materials
is one of the most advance topics, which researchers have found. Friction stir welding (FSW)
technology is feasible to join dissimilar materials because of its solid-state nature.[1].
Friction stir welding (FSW) is feasible methods by which Cu–Al dissimilar materials
can be joined together [2,3]. Friction-stir welding is a solid-state welding technique in which
plates are joined by mechanical processes. This joining technique is used in the welded joint
of aluminium alloys and copper. [4] Reported on the material flow of FS lap-weld of Al-Cu.
According to them, the interface in the central region of the weld moves considerably into the
bottom plate because of the circle-like vortex flow of the materials caused by the probe
threads.
Higher welding speeds reduced vertical transport, especially on the retreating side.
They attributed the reduction of vertical transport to fewer revolutions over the distance of
the weld. [5] From previous works, we conclude that a suitable flow of the softened material
contributes to the complete formation of a weld. The degree of material softening depends on
the heat input, which is determined by the weld parameters largely depending on the welding
speed and rotation rate,[6]. The flow of material in friction stir welding has occurred due to
the rotational and longitudinal movement of the tool [7].
2.METHODE
The focus of the research work will be concentrated in the mechanical performance and the stir
zone microstructure by FSW lap. All the testing of the welded part will be lap welding joints. Lap
welding joints are used most often to joint two pieces with differing thicknesses together. Also
considered a fillet type, the weld can be made on one or both sides. A Lap Joint is formed when 2
pieces are placed in an overlapping pattern on top of each other.
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2.1 Tools
1. Milling machine
2.Calipers
3. File
4. Clamp device
5.Sandpaper
6.Vice
7. Supporting specimen
8.Autosol
9.Cleaner machine
10.Microstructure
11.Micro Vickers hardness test
2.2 Research Materials
2. Test specimens
2.Tool joint
2.3 Location research
3. To make a probe and pin at SMK Negeri 2 Solo.
4. Process welding FSW did at Akprind Laboratorium Yorkyakarta.
5. Microstructure test at laboratorium Universitas Muhammadiyah Surakarta (UMS).
6. Doing the hardness test at Akademic Teknology Waega Surakarta.
Table 5 Important processes parameters and their limits used FSW
S No. Input parameter Parameter
Designation
Unit Design -1 (Lower)
Limits +1(Upper)
1 Rotation speed N Rpm 1500 2500
2 Welding speed V Mm/min 30 80
3 Plunging speed P Mm/min 10 20
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2.4 Flowchart diagram
Figure 4 Flowchart Diagram
Literature review and materials selection
Preparation of Equipment and
Materials
WELDING BY FRICTION STIR WELDING
TOOL JOINT
AISI 4340 TOOL JOINT
EMS 45
HARDNESS TEST
MAKING SPECIMEN TESTING
WELDING RESULT
ANALYSIS AND DISCUSSION MICROSTRUCTURE
TEST
END
START
CONCLUSION
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3.RESULT AND DISCUSSION
3.1 Welding Result
Welding result is observed and analyzed visually first before damaging the test, the following
result as below:
Table 6 Welding Result Friction Stir Welding
Welding Aluminium and Copper
Parameter Result friction stir welding
-Rotational speed for Cu and Al: 1500 rpm -weld flash
-Feed rate: 8 mm/mins -Broken hole
-tilt angle 0.3 degree -Smooth welding surface is
not smooth, has cracks on Cu
-Depth phunng : 1.2 mm - stable welding Al and Cu
3.2 Microstructure
The microstructures of aluminium and copper are presented, as shown in Fig.25 and Fig.26,
friction stir welding results have several welding areas, that is a base metal and weld nuggets.
1. Base metal
The base metal is an area that is not affected by good welding heat or mix.
Figure 25 photomicrograph base metal of copper
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Figure 26 photomicrograph base metal of Aluminium
2.Nugget
(The Stir zone) the zone which had to lose shape, as shown in Fig.27 and Fig.28, and it is a
resultant of rotating tool pin and under processing conditions, and circumference structure
develops. The interface between the main material is relatively diffusive heat and it's quite sharp
toward the advancing side. It has been found that there is an optimum rotational speed for a given
a move speed that gives the highest strength and thickness for the nugget zone.
The Stir zone on the Copper side
Figure 27 Nugget zone on the copper surface from a top view
The Stir zone on Aluminium side
Figure 28 Nugget zone on Aluminium’s surface bottom view
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Nugget ( The Stir zone ) has taken by microstructure after welding of two material copper
and aluminium as shown in a Fig.29, the material surface which experiences extremes
deformation and is a consequence of rotating tool.
Aluminium surface
On Nugget areas
Copper surface
On Nugget areas
Figure 29 Nugget zone’s surface of Al and Cu
(a)
(b)
(c)
Figure 30 (a) surface of copper in the centre of welding side,(b) a broken hole on the
welding side between Cu and Al and (c) is a surface of the aluminium.
Non-welding zone of two material, as shown in Fig.31, is the area that has not touched by a
tool pin when it welded but these two specimens have collided together by it heat from
welding zone.
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(a)
(b)
Figure 31 a micrograph surface of both alloys in the non-welding affected (a) is a
aluminium surface and (b) is a copper surface.
3.3 Hardness Test
The hardness test of this experiment designed, as shown in Fig.32, has using Vicker machine at
Akademic Teknologi Warga Surakarta(ATW Solo). This test has used 2 specimens for testing.
Parameter test specimen (welding Aluminium and Copper by lap-joint)
-Force load 0.98 Newton
- Holding time for 15 second
- Distant between a point testing is 2mm
This hardness test using standard ASTM E92 for the testing process.
cm
Figure 32 Hardness test design
Retreating
side
Advancing
side
2
2 mm
5.4 cm
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Hardness test results displayed in a form and graphical form, as shown in Fig.33,34 and 35,
to determine the relationship between the hardness value and the distance of the test point
from the middle point of the specimen. And hardness value data from research that has been
obtained can be made a graph of the relationship between the hardness value with the
distance of each test.
Micro Vickers Hardness Cu
180
160
140
120 100
Har
dnes
s(
HV
)
80
60
40
20
0
-5 -4 -3 -2 -1 0 1 2 3 4 5
Point
Figure 33 Graph of Copper hardness welding
This figure is shown a result of micro Vickers hardness test of copper.
Micro Vickers Hardness Al
45
40
(
35
Har
dnes
s
HV
)
30
25
20
15
10
5
-5 -4 -3 -2 -1 0 1 2 3 4 5 Point
Figure 34 Graph of Aluminium hardness weld
10
Micro Vickers Hardness between Al and Cu
180
160
140
120
100
Har
dnes
s s(
HV
) 80
60
40
20
0
-5 -4 -3 -2 -1 0 1 2 3 4 5
Point
Figure 35 Comparison Graph of Aluminium and copper hardness welding
This figure is shown a comparison result of a micro Vickers hardness test of copper and
aluminium.
4.CLOSING
4.1 Conclusion
Based on analysis and calculation from the data that obtained from the test results can be
concluded:
1. Specify details a current state of the friction stir welding of Aluminium to copper.
2. .Base on photo microstructure of specimens after friction stir welding between Aluminium and
Copper can be concluded its should sandpapering until a specimen clean and clear and its has to
using the chemical to support a specimen to get a clearer specimen to easy to took photo micro
and get the stable result.
3. Base on hardness test of specimens after friction stir welding between Aluminium and
Copper we choose standard ASTM E92 to prove the result. And the surface of the
specimen must be equal.
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4.2 Suggestion
From the experiment, several things can be an improvement from this experiment such as:
1. The preparation of a tool should be chosen appropriately with the materials that will use
for experiment and should follow the standard as well.
2.Should study carefully to select a tool joint for Friction stir welding on copper that must
be stronger than tool joint of friction stir welding on Aluminium because it is different
alloys and properties.
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