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Cited by 8Advanced Welding Techniques AnalysisWelding Techniques and Residual StressesEngineering Structural Analysis Methods

Continuous Drive Friction Welded Al/Cu Joints Produced Using Short Welding Time, Elevated Rotational Speed, and High Welding Pressures

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Milašinović, Veljko, Alil, Ana, Milašinović, Mijat, Vencl, Aleksandar, Hatala, Michal, Dikić, Stefan, Gligorijević, Bojan·2024·Materials
DOI 10.3390/ma17133284PMC PMC11243190
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Abstract

The present study aimed to enhance the efficiency and efficacy of the Al/Cu joint production process implemented by the company VEMID Ltd., Jagodina, Serbia, by attaining sound joints within a very short welding time. For this purpose, the present study aimed at investigating the accuracy and the quality of the continuous drive friction welding (CDFW) process, as well as the optimum combination of CDFW parameters with highest joint efficiency in terms of investigated properties. The accuracy was estimated through an analysis of temperature–time curves recorded during CDFW using an infrared camera. The quality was evaluated through an investigation of the properties of Al/Cu joints produced using different friction (66.7, 88.9, and 133.3 MPa) and forging (88.9, 222.2, and 355.6 MPa) pressures and a constant total welding time (4 s) and rotational speed (2100 rpm). Thermal imaging with an infrared camera demonstrated that the actual total welding time was 15% longer compared to the nominal value. This was attributed to the slow pressure response of the pneumatic brake system. The relative changes in the maximum surface temperature (TMS) during the CDFW process corresponded to changes in welding pressures, indicating the potential of the thermal imaging method for monitoring and assessing this process. A preliminary investigation demonstrated that Al/Cu joints produced using welding pressures less than 88.9 MPa often displayed the presence of non-joined micro-regions at the Al/Cu interface and a significant thickness of interfacial Al2Cu (up to 1 µm). However, when friction pressure was set at 66.7 MPa, an increase in the forging pressure to 222.2 MPa eliminated the presence of non-joined micro-regions and reduced the thickness of Al2Cu to 0.5 µm on the average level. These Al/Cu joints achieved the highest joint efficiencies in terms of strength (100%) and ductility (61%). They exhibited an electrical conductivity higher than 92% of the theoretical value. A further increase in any welding pressure produced similar or deteriorated properties, accompanied by an increase in the consumption of raw materials and energy. Such turn of events was counterproductive to the original goal of increasing the efficiency and efficacy of the CDFW process.

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Authors
Milašinović, V., Alil, A., Milašinović, M., Vencl, A., Hatala, M., Dikić, S., & Gligorijević, B.
Affiliations
  • VTM Solutions, Slavke Đurđević 19/2, 35000 Jagodina, Serbia
  • University of Belgrade (RS)
  • Becchis Osiride Ltd., Dragoslava Srejovića 89, 34000 Kragujevac, Serbia
  • Technical University of Košice (SK)
Corresponding author
Vencl, Aleksandar
ORCID
Venue
Materials
Publisher
MDPI AG
Published
2024-07-03
Volume
17
Issue
13
Pages
3284
ISSN
1996-1944 (ISSN-L)
DOI
10.3390/ma17133284
PMC
PMC11243190
OpenAlex
W4400280724
Cited by
8
References
0
Citations by year
2026: 3 · 2025: 3 · 2024: 2
FWCI
1.07
Type
journal article
Language
en
Open access
Licence
Locations
  • Materials (publishedVersion, cc-by)
  • PubMed Central (publishedVersion, cc-by)
  • PubMed (publishedVersion)
  • TechnoRep (University of Belgrade – Faculty of Technology and Metallurgy) (submittedVersion, cc-by)
  • CER (University of Belgrade, Institute of Chemistry, Technology and Metallurgy) (submittedVersion, cc-by)
  • DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion)
  • Materials (submittedVersion, cc-by)
Funders
  • Ministry of Science, Technological Development and Innovation of the Republic of Serbia (451-03-47/2023-01/200287, 451-03-47/2023-01/200026, 451-03-65/2024-03/200105, 451-03-47/2023-01/200135, IF 920, APVV-21-0228, VEGA 1/0391/22)
  • Innovation Fund of the Republic of Serbia (451-03-47/2023-01/200287, 451-03-47/2023-01/200026, 451-03-65/2024-03/200105, 451-03-47/2023-01/200135, IF 920, APVV-21-0228, VEGA 1/0391/22)
  • Slovak Research and Development Agency (451-03-47/2023-01/200287, 451-03-47/2023-01/200026, 451-03-65/2024-03/200105, 451-03-47/2023-01/200135, IF 920, APVV-21-0228, VEGA 1/0391/22)
  • Ministry of Education, Science, Research, and Sport of the Slovak Republic (451-03-47/2023-01/200287, 451-03-47/2023-01/200026, 451-03-65/2024-03/200105, 451-03-47/2023-01/200135, IF 920, APVV-21-0228, VEGA 1/0391/22)
Topics
  • Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
  • Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
  • Physical Sciences › Engineering › Mechanical Engineering › Engineering Structural Analysis Methods
Keywords
continuous drive friction welding, aluminum-copper joints, dissimilar metal joining, welding pressure, friction pressure, rotational speed, welding time, infrared thermography, temperature-time curves, Al2Cu intermetallic, joint efficiency, electrical conductivity, ductility, pneumatic brakes

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