Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity
In dissimilar friction stir welding (FSW) joints, the stir zone, where brittle IMCs are extensively distributed, is usually the origin of crack initiation, which can severely deteriorate the joint performance. To improve the mechanical properties of Al-Cu friction stir weld joints by optimizing the...
| Main Authors: | , , , , , , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2025
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| Online Access: | http://umpir.ump.edu.my/id/eprint/44311/ http://umpir.ump.edu.my/id/eprint/44311/1/Strength-ductility%20synergy%20in%20dissimilar%20friction%20stir%20welded%20Al-Cu.pdf |
| _version_ | 1848827074819653632 |
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| author | Hou, Wentao Hu, Yongsheng Qiang, Fei Shen, Zhikang Chen, Jianbin Li, Junping Huda, Nazmul Luqman Hakim, Ahmad Shah Shen, Yifu |
| author_facet | Hou, Wentao Hu, Yongsheng Qiang, Fei Shen, Zhikang Chen, Jianbin Li, Junping Huda, Nazmul Luqman Hakim, Ahmad Shah Shen, Yifu |
| author_sort | Hou, Wentao |
| building | UMP Institutional Repository |
| collection | Online Access |
| description | In dissimilar friction stir welding (FSW) joints, the stir zone, where brittle IMCs are extensively distributed, is usually the origin of crack initiation, which can severely deteriorate the joint performance. To improve the mechanical properties of Al-Cu friction stir weld joints by optimizing the stir zone microstructure and the distribution of IMCs particles, an eccentric welding tool was adopted to perform dissimilar friction stir welding of Al alloy to commercially pure Cu. Microstructure evolution of the stir zone was investigated by varying the value of pin eccentricity ranging from 0 to 0.4 mm using scanning electron microscopy (SEM), X-ray spectroscopy (EDS), optical microscopy (OM) and transmission electron microscopy (TEM). Mechanical properties, including ultimate tensile strength and elongation, of the samples produced with different eccentricity were evaluated by means of quasi-static uniaxial tensile test. The results indicate that with the application of pin eccentricity, a strength-ductility synergy was achieved, where the joint ultimate tensile strength (UTS) increased by 32 % to ~198 MPa with 0.4 mm eccentricity from ~150 MPa without pin eccentricity, and the corresponding elongation of the Al-Cu joints was also significantly increased, reaching up to 10.3 %. The enhanced strength-ductility synergy observed in the joints can be attributed to the significant refinement and more uniform distribution of Cu and intermetallic compound (IMC) particles within the stir zone, facilitated by the intensified straining effect of the eccentric pin. This study presents a novel approach for the fabrication of Al-Cu dissimilar joints that achieves superior strength while maintaining satisfactory ductility, thereby offering a balanced solution for the improvement of joint performance. |
| first_indexed | 2025-11-15T03:54:56Z |
| format | Article |
| id | ump-44311 |
| institution | Universiti Malaysia Pahang |
| institution_category | Local University |
| language | English |
| last_indexed | 2025-11-15T03:54:56Z |
| publishDate | 2025 |
| publisher | Elsevier |
| recordtype | eprints |
| repository_type | Digital Repository |
| spelling | ump-443112025-04-17T00:47:14Z http://umpir.ump.edu.my/id/eprint/44311/ Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity Hou, Wentao Hu, Yongsheng Qiang, Fei Shen, Zhikang Chen, Jianbin Li, Junping Huda, Nazmul Luqman Hakim, Ahmad Shah Shen, Yifu TA Engineering (General). Civil engineering (General) TJ Mechanical engineering and machinery TN Mining engineering. Metallurgy In dissimilar friction stir welding (FSW) joints, the stir zone, where brittle IMCs are extensively distributed, is usually the origin of crack initiation, which can severely deteriorate the joint performance. To improve the mechanical properties of Al-Cu friction stir weld joints by optimizing the stir zone microstructure and the distribution of IMCs particles, an eccentric welding tool was adopted to perform dissimilar friction stir welding of Al alloy to commercially pure Cu. Microstructure evolution of the stir zone was investigated by varying the value of pin eccentricity ranging from 0 to 0.4 mm using scanning electron microscopy (SEM), X-ray spectroscopy (EDS), optical microscopy (OM) and transmission electron microscopy (TEM). Mechanical properties, including ultimate tensile strength and elongation, of the samples produced with different eccentricity were evaluated by means of quasi-static uniaxial tensile test. The results indicate that with the application of pin eccentricity, a strength-ductility synergy was achieved, where the joint ultimate tensile strength (UTS) increased by 32 % to ~198 MPa with 0.4 mm eccentricity from ~150 MPa without pin eccentricity, and the corresponding elongation of the Al-Cu joints was also significantly increased, reaching up to 10.3 %. The enhanced strength-ductility synergy observed in the joints can be attributed to the significant refinement and more uniform distribution of Cu and intermetallic compound (IMC) particles within the stir zone, facilitated by the intensified straining effect of the eccentric pin. This study presents a novel approach for the fabrication of Al-Cu dissimilar joints that achieves superior strength while maintaining satisfactory ductility, thereby offering a balanced solution for the improvement of joint performance. Elsevier 2025-03 Article PeerReviewed pdf en http://umpir.ump.edu.my/id/eprint/44311/1/Strength-ductility%20synergy%20in%20dissimilar%20friction%20stir%20welded%20Al-Cu.pdf Hou, Wentao and Hu, Yongsheng and Qiang, Fei and Shen, Zhikang and Chen, Jianbin and Li, Junping and Huda, Nazmul and Luqman Hakim, Ahmad Shah and Shen, Yifu (2025) Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity. Materials Today Communications, 44 (111949). pp. 1-10. ISSN 2352-4928. (Published) https://doi.org/10.1016/j.mtcomm.2025.111949 https://doi.org/10.1016/j.mtcomm.2025.111949 |
| spellingShingle | TA Engineering (General). Civil engineering (General) TJ Mechanical engineering and machinery TN Mining engineering. Metallurgy Hou, Wentao Hu, Yongsheng Qiang, Fei Shen, Zhikang Chen, Jianbin Li, Junping Huda, Nazmul Luqman Hakim, Ahmad Shah Shen, Yifu Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity |
| title | Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity |
| title_full | Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity |
| title_fullStr | Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity |
| title_full_unstemmed | Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity |
| title_short | Strength-ductility synergy in dissimilar friction stir welded Al-Cu joints via introducing pin eccentricity |
| title_sort | strength-ductility synergy in dissimilar friction stir welded al-cu joints via introducing pin eccentricity |
| topic | TA Engineering (General). Civil engineering (General) TJ Mechanical engineering and machinery TN Mining engineering. Metallurgy |
| url | http://umpir.ump.edu.my/id/eprint/44311/ http://umpir.ump.edu.my/id/eprint/44311/ http://umpir.ump.edu.my/id/eprint/44311/ http://umpir.ump.edu.my/id/eprint/44311/1/Strength-ductility%20synergy%20in%20dissimilar%20friction%20stir%20welded%20Al-Cu.pdf |