Microstructures and properties analysis of dissimilar metal joint in the friction stir welded copper to aluminum alloy

This paper mainly concentrated on the feasibility of friction stir welding of dissimilar metal of aluminum alloy to copper （I2） and a preliminary analysis of welding parameters influencing on the microstructures and properties of joint was carried out. The results indicated that the thickness of workpiece played an important role in the welding parameters which could succeed in the friction stir welding of dissimilar metal of copper to aluminum alloy, and the parameters were proved to be a narrow choice. The interfacial region between copper and aluminum in the dissimilar joint was not uniformly mixed, constituted with part of incomplete mixing zone, complete mixing zone, dispersion zone and the most region＇ s boundary was obvious. Meantime a kind banded structure with inhomogeneous width was formed. The intermetallic compounds generated during friction stir welding in the interfacial region were mainly CugAl4, Al2Cu etc, and their hardness was higher than oihers.

Corrosion behavior of aluminum/steel dissimilar metals friction stir welding joint

The corrosion performance of aluminum/steel contact and aluminum/steel FSW joint in 3.5 wt.%NaCl solution were analyzed using potentiostatic tests.The post-corrosion microstructure of the welding joint was characterized by optical microscope(OM),scanning electron microscopy(SEM)and energy dispersive spectroscopy(EDS).The results showed that the localized corrosion of FSW joint of Al/steel dissimilar metals mainly initiated at the interface transition zone(ITZ).Precipitation of intermetallic compounds(IMCs)and Fe-rich phase particles in ITZ accelerated the corrosion of the FSW joint.This phenomenon has been attributed to distinct corrosion potentials between IMCs and steel,aluminum base metal.The corrosion resistance sequence of IMCs in ITZ is Fe_(3)Al>FeAl>Fe_(2)Al_(5).

Effect of metallic phase content on mechanical properties of (85Cu-15Ni)/(10NiO-NiFe_2O_4) cermet inert anode for aluminum electrolysis

(85Cu-15Ni)/(10NiO-NiFe2O4) cermets were prepared with Cu-Ni mixed powders as toughening metallic phase and 10NiO-NiFe2O4 as ceramic matrix. The phase composition, microstructure of composite and the effect of metallic phase content on bending strength, hardness, fracture toughness and thermal shock resistance were studied. X-ray diffraction analysis indicates the coexistence of (Cu-Ni), NiO and NiFe2O4 phases in the cermets. Within the content range of metallic phase from 0% to 20% (mass fraction), the maximal bending strength (176.4 MPa) and the minimal porosity (3.9%) of composite appear at the metallic phase content of 5%. The fracture toughness increases and Vickers’ hardness decreases with increasing metal content. When the thermal shock temperature difference (△t) is below 200 ℃, the loss rate of residual strength for 10NiO-NiFe2O4 ceramic is only 8%, but about 40% for (85Cu-15Ni)/(10NiO-NiFe2O4) cermets. As △t is above 200 ℃, the residual strength sharply decreases for sample CN0 and falls slowly for samples CN5-CN20.

Brazing 6061 aluminum alloy with Al-Si-Zn filler metals containing Sr

Al-6.5Si-42Zn and Al-6.5Si-42Zn-0.09Sr filler metals were used for brazing 6061 aluminum alloy. Air cooling and water cooling were applied after brazing. Si phase morphologies in the brazing alloy and the brazed joints were investigated. It was found that zinc in the Al-Si filler metals could reduce the formation of eutectic Al-Si phase and lower the brazing temperature at about 520℃. Adding 0.09wt% Sr element into the Al-6.5Si-42Zn alloy caused a-Al phase refinement and transformed acicular Si phase into the finely fiber-like. After water cooling, Zn element dissolved into the Al-Si eutectic area, and η-Zn phase disappeared in the brazed joints. Tensile strength testing results showed that the Sr-modified filler metal could enhance the strength of the brazed joints by 13% than Al-12Si, while water-cooling further improved the strength at 144 MPa.

A High-Fe Aluminum Matrix Welding Filler Metal for Hardfacing Aluminum-Silicon Alloys

A high Fe containing aluminum matrix filler metal for hardfacing aluminum silicon alloys has been developed by using iron,nickel,and silicon as the major strengthening elements,and by measuring mechanical properties,room temperature and high temperature wear tests,and microstructural analysis.The filler metal,which contains 3.0%-5.0% Fe and 11.0%-13.0% Si,exhibits an excellent weldability.The as cast and as welded microstructures for the filler metal are of uniformly distribution and its dispersed network of hard phase is enriched with Al Si Fe Ni.The filler metal shows high mechanical properties and wear resistance at both room temperature and high temperatures.The deposited metal has a better resistance to impact wear at 220℃ than that of substrate Al Si Mg Cu piston alloy;at room temperature,the deposited metal has an equivalent resistance to slide wear with lubrication as that of a hyper eutectic aluminum silicon alloy with 27% Si and 1% Ni.

Dynamic Behaviour of Cast A356/Al₂O₃Aluminum Metal Matrix Nanocomposites

The present work includes the study of the dynamic properties of the nanocomposites specimens. The dynamic properties of A356/Al2O3 nanocomposites were investigated through different fabrication conditions. The A356/Al2O3 nanocomposites specimens were fabricated using a combination between the rheocasting and squeeze casting routes. The composites were reinforced with Al2O3 particulates of 60 and 200 nm and different volume fractions up to 5 vol.%. The dynamic properties of the A356/Al2O3 nanocomposites were investigated through measuring the dynamic properties of specimens. Free vibration method is used to measure frequency response (fn ), and damping factor (ξ). The viscoelastic properties such as loss factor η, storage modulus (E'), and loss modulus (E") were obtained. The results concluded that, the dynamic properties of nanocomposites were improved by increasing the volume fractions of nanoparticulates and decreasing the nanoparticulates size. The results indicated also that, the damping factor, and the related parameters (η, E' and E") was strongly affected by increasing both volume fraction and the particulates.

Microstructure characteristics of dissimilar metal weld between aluminum alloy and brass

Dissimilar metal joining between 5A02 aluminum alloy and H62 brass sheets was conducted by gas tungsten arc welding with Zn-15% Al and Al-12% Si flux-cored filler wires. The microstructure in the weld and distribution of major alloying elements in the intelfacial layer were examined, and the tensile strength of the resultant joints was measured. Pores appeared in the weld made with Zn-15% Al flax-cored filler wire, the interracial layer mainly consisted of AlCu phase, and the specimens fractured through the weld with tensile strength of 129 MPa. When Al-12% Si flux-cored filler wire was used, Cu diffused into the weld and Al2 Cu phase formed, and the specimens fractured along the interfacial layer with tensile strength of 122 MPa.

Multichip on Aluminum Metal Plate Technology for High Power LED Packaging

Multichip on Ahnnintnn Metal Plate（MOAMP） technology with simple structure and low thermal resistance is developed for effective heat reratrval of Light Emitting Diode（LED） p-n junction and LED lighting module to have high reliability. The thermal resistance of LED modules was numerical and experimental. Thermal resistance from the jtnction to aluminten metal plate, considering input power of IFD module using MOAMP technology, is 3.02 K/W, 3.23 K/W for the measured and calculated, respectively. We expect that the reported MOAMP technology with low thermal resistance will be a promising solution for high power LED fighting modules.

Influence of shielding gas on the mechanical and metallurgical properties of DP-GMA-welded 5083-H321 aluminum alloy

In the present research, 6-mm-thick 5083-H321 aluminum alloy was joined by the double-pulsed gas metal arc welding （DP-GMAW） process. The objective was to investigate the influence of the shielding gas composition on the microstructure and properties of GMA welds. A macrostructural study indicated that the addition of nitrogen and oxygen to the argon shielding gas resulted in better weld penetration. Furthermore, the tensile strength and bending strength of the welds were improved when oxygen and nitrogen （at concentrations as high as approximately 0. 1vol%） were added to the shielding gas; however, these properties were adversely affected when the oxygen and nitrogen contents were increased further. This behavior was attributed to the formation of excessive brown and black oxide films on the bead surface, the formation of intermetallic compounds in the weld metal, and the formation of thicker oxide layers on the bead surface with increasing nitrogen and oxygen contents in the argon-based shielding gas. Analysis by energy-dispersive X-ray spectroscopy revealed that most of these compounds are nitrides or oxides.

PREDICTION OF PATH-DEPENDENT FAILURE IN ALUMINUM SHEET METALS UNDER FORMING OPERATIONS

An approximate macroscopic yield criterion for anisotropic porous sheet metals is adopted in a failure prediction methodology that can be used to investigate the failure of sheet metals under forming operations. This failure prediction methodology is developed based on the Marciniak-Kuczynski approach by assuming a slightly higher void volume fraction inside randomly oriented imperfecte analysis. Here, a nonproportional deformation history including relative rotation of principal stretch directions is identified in a selected critical element of an aluminum sheet from a FEM fender forming simulation. Based on the failure prediction methodology, the failure of the critical sheet element is investigated under the non-proportional deformation history. The results show that thiven non-proportional deformation history.

Preparation of Rod-like Aluminum Doped Zinc Oxide Powders by Sol-gel Technique Using Metal Chlorides and Acetylacetone Precursors

Al-doped ZnO(AZO) powders were prepared by using metal chloride precursors and the sol-gel technique. IR peaks observed at 1590 cm-1 and 1620 cm-1indicated the formation of metal chelate as a consequence of the addition of acetylacetone to the metal chloride solution. TG-DSC analysis of the AZO gels confirmed the formation of metal chelate as evidenced by the development of several weight loss peaks accompanied by the introduction of new endothermic peaks. The resulting AZO gels were annealed at 500, 600, and 800 ℃ to study the effect of annealing temperature. XRD and SEM results showed that crystallization of AZO gels takes place around 600 ℃. Hexagonal wurtzite structure was identified as the main phase for all the samples. In addition, small shift of the XRD(002) peak coupled with XPS results from the AZO powders confirmed the successful doping of the ZnO powders. Micron sized rod-like AZO powders were uniform in dimension and morphology and remained stable even at 800 ℃.

Microstructure and mechanical properties of dissimilar joint between aluminum and aluminum-coated steel by cold metal transfer process

Two dissimilar materials, aluminum alloy and aluminum-coated steel, were joined by cold metal transfer process using AlSi5 filler wire. To this end, the steel was coated with Al-Si. The steel did not melt and aluminum was melt to form the joint during the process, it was actually cold metal transfer welding-brazing. The macrostructure, microstructure, alloy element distribution, and inter-metallic compounds were analyzed by optical microscopy, scanning electron microscopy, and energy dispersive spectroscopy. It was found that the Al-Si coating dissolved into the weld metal. The pre-existing thin Fe-Al- Si ternary inter-metallic compounds in the interface between the Ak-Si coating layer and base metal steel also partially dissolved into the weld zone, tending to reduce the thickness of inter-metallic compounds. Approximate 3 μm thick undissolved intermetallic compound was found at the interface after welding which could guarantee sound bonding strength in dissimilar materials joining. The sample was fractured at the fusion zone near the aluminum side in the tensile test. The ultimate tensile strength was about 156 MPa, and the fracture mode is ductile failure in nature according to its morphology.

Influence of oxidant KMnO_4 on film-forming process of rare earth metal conversion coating on LY12 aluminum alloy

A Cu/Al galvanic couple was established to study the influence of the oxidantKMnO_4 on the film-forming process of rare earth metal (REM) conversion coating on LY12 aluminumalloy. It is found that the galvanic couple simulative experiment accords with the actual immersion,and it can be substantially used to simulate the behavior of LY12 aluminum alloy in thefilm-forming process. It is showed that the formation of the coating is quickened in CeCl_3 solutioncontaining KMnO_4 compared with that not containing KMnO_4. XPS results reveal that the coatingformed on cathode is composed of oxide or hydroxide of Ce and Mn, so the mechanism of formation ofREM conversion coating changes when KMnO4 is added.

Analysis of Laser Micro Welding of Copper-Aluminum Dissimilar Metals and Its Mechanism

Micro welding of dissimilar metals can meet many performance requirements for modern engineering structures. In this experiment, laser micro welding of copper-aluminum dissimilar metals was conducted with an HWLW-300A energy negative feedback Nd:YAG pulse laser. By using the overlap welding method with copper on aluminum, with the laser energy being distributed unevenly, good weld joints were obtained. In this paper, the welding mechanism was analyzed from aspects such as welding temperature and the specific heat capacity of the solid metal. Existing defects were identified, and a feasible improvement scheme was proposed.

Numerical simulation of current distribution in metal pad of aluminum reduction cells

Based on the numerical calculation of 3-D potential distribution in aluminum reduction cells, current distribution in the metal pad is calculated under the following conditions: 1) pot ledge ideally formed; 2) ledge extension to below anode; 3) different metal heights; 4) AC and 5) Spike. It is found that J_y in metal pad increases first to a highest point and then decreases along anode length. At normal status, the largest J_y is about 0.4A/cm^2 and it locates at about 2/3 of anode length. With longer ledge, the maximum value of J_y decreases and its position moves center-ward. The longer the side ledge, the larger the negative current flowing center-ward at side channel. J_z in metal pad increases with anode length and it is not affected by metal height; while J_y increases with metal height. At AC, current flows toward metal under new anode. At spike, current concentrates at spike rather than evenly distributes. Normally, J_x is almost negligible in metal pad.

Non-metallic Inclusions in Continuously Cast Aluminum Killed Steels

In aluminum killed steels, the size, shape, quantity and formation of non-metallic inclusions in ladle steel (before and after RH vacuum treatment) and in tundish as well as in slabs were studied by EPMA (Electron Probe Microanalysis) and by analyzing the total oxygen. The results showed that in the slabs the total oxygen was quite low and the inclusions discovered were mainly small-sized angular alumina inclusions. This indicates that most inclusions have been removed by floating out during the continuous casting process. In addition, the countermeasures were discussed to decrease the alumina inclusions in the slabs further.

Solidification crack susceptibility of aluminum alloy weld metals

The susceptibilities of the three aluminum alloys to solidification crack were studied with trans-varestraint tests and tensile tests at elevated temperature. Their metallurgical characteristics, morphologies of the fractured surface and dynamic cracking behaviors at elevated temperature were analyzed with a series of micro-analysis methods. The results show that dynamic cracking models can be classified into three types. The first model has the healing effect which is called type A. The second is the one with deformation and breaking down of metal bridge, called type B. The last one is with the separation of liquid film along grain boundary, called type C. Moreover, the strain rate has different effects on crack susceptibility of aluminum alloys with different cracking models. ZL101 and 5083 alloys belong to type A and type C cracking model respectively, in which strain rate has greater effect on eutectic healing and plastic deformation of metal bridge. 6082 alloy is type B cracking model in which the strain rate has little effect on the deformation ability of the liquid film.

增强体表面改性在高导热金属基复合材料中的应用

随着电子技术的高速发展和电子器件的更新换代,电子封装材料的性能需求越来越高。金属基复合材料,尤其是铝基和铜基复合材料具有高导热、低膨胀、高稳定性等特点,是具有广阔应用前景的电子封装材料。然而,金刚石、石墨烯、硅等增强体与基体的润湿性差,或者在高温下与基体发生有害的界面反应,限制了此类高导热金属基复合材料的开发和应用。本文简述了金属基复合材料的界面研究进展,结合影响金属基复合材料界面结合的因素,提出了几种改善界面结合的方法。增强体表面改性是改善金属基复合材料界面的重要途径之一,常用工艺有磁控溅射法、化学气相沉积法、溶胶凝胶法、化学镀法等;最后,对增强体表面改性在高热导金属基复合材料中的应用进行分析和展望。

基于Ni/Zn中间层的6061铝合金/Q355钢电阻点焊接头组织与性能

【目的】采用预置Ni/Zn中间层的方法进行Q355钢/6061铝合金异种金属的电阻点焊研究。【方法】在不同焊接时间、焊接电流及电极压力下分别对6061铝合金与Q355钢的电阻点焊工艺进行对比分析并获得最优电阻点焊工艺参数,然后采用在铝合金板与钢板之间添加Ni/Zn箔片作为中间层的方法来研究Ni/Zn中间层对铝/钢电阻点焊接头组织与性能的影响,并利用光学显微镜、扫描电镜、能谱分析及拉伸试验机等方法对含Ni/Zn中间层的铝/钢电阻点焊接头微观组织、元素占比、第二相的变化及抗拉剪力进行了研究。【结果】结果表明,铝/钢点焊接头由铝一侧熔核,钢一侧熔核和结合界面处的金属间化合物组成,具有典型的双熔核特征。通过在6061铝合金与Q355钢的中间分别增加Ni与Zn箔片来阻碍脆硬的Al-Fe金属间化合物的生成量。添加Ni中间层的接头界面区生成了韧性较好的Al3Ni,从而阻碍了硬而脆的Al-Fe金属间化合物的形成。添加Zn中间层的接头界面区生成了一定量的Fe2Al5Zn0.4,使Al-Fe金属间化合物层的厚度减小至2.88μm,最大抗拉剪力达到4.69 kN。【结论】添加Ni/Zn中间层后,铝/钢电阻点焊接头的熔核直径与抗拉剪力均有所提升,同时Ni元素的添加会在铝/钢界面处生成韧性较好的Al3Ni相,从而阻碍了Al-Fe金属间化合物的生成。

Cu对铝/钢CMT熔钎焊接头界面区组织的影响研究

采用冷金属过渡方法,以AlSi5焊丝为填充金属,在5052铝合金和镀锌钢板之间添加铜箔片进行搭接熔钎焊,使用扫描电子显微镜结合能谱分析和拉伸试验机对接头的界面区组织与性能进行研究。结果表明,未加入铜箔时,界面区组织主要由FeAl_(3)金属间化合物组成;铜箔的加入使得界面区组织中新生成了CuAl_(2)金属间化合物,同时改善了Zn在界面区的分布。Zn固溶于Al中,一定程度上抑制了Fe-Al金属间化合物产生。加入铜箔后的试样断裂位置发生改变,接头的承载能力与未加入铜箔的相近。