Effect of Fe particles on the microstructural evolution and mechanical properties of friction welded Al-Cu components

Metals like aluminium (Al) and copper (Cu) are excessively used in electrical, automobile, nuclear, and structural applications because of their desirable electrical and mechanical properties. Joining of components made of pure Al and Cu is one of the challenging areas of research, because of the rapid oxidation characteristics of Al and intense formation of Al-Cu intermetallics in the joint interface. The existing welding techniques such as laser welding, metal inert gas welding, and arc welding have hardships in the development of joint between Al and Cu with desirable metallurgical and mechanical properties. Friction welding is a solid-state joining technique that utilises the frictional heat to develop the joint between the materials at relatively low temperatures. In this study, the effect of friction welding parameter on the microstructure and mechanical properties of friction welded pure Al and Cu were studied. Besides, the microstructural evolution in friction welding Al and Cu with Fe particle reinforcement was analysed. The elemental composition and phases were analysed using energy dispersive x-ray spectroscopy and x-ray diffraction analysis. The microstructural analysis revealed that Fe particles reduced the formation of Al-Cu intermetallic phases at the joint interface.