Evaluation of the influence of upset stage on joint properties of friction welded dissimilar aluminum-copper cast alloys

Abstract

Friction welding was applied to dissimilar aluminum cast bars alloyed with 2 and 8% copper and the effects of upset time on joint properties were evaluated in this study. The welding process was carried out by a vertical milling machine. Tensile test results show that the ultimate tensile strength increased with an increase in upset time and it reached 88% for Al-2%Cu and 74% for Al-8%Cu base metals. The heat affected zone, thermo-mechanical affected zone, and weld metal were detected in this joint by optical examination, in addition to the base metals. A peak temperature of 436 °C was measured in the weld zone. Hardness values also varied according to microstructural changes. The highest hardness values were detected in the weld metal and its average hardness was 217 Brinell.