The Mechanism Research On The Friction Stir Welding Procedure Of Aluminum-to-copper Dissimilar Materials

Compared with the existing problem of the numerical simulation that the simulation results of the real degree is not high for its building on a large number of assumptions of the simulate conditions, the simulation results of physical simulation are more reliable due to more similar to the simulation environment. In this paper, the clay is used as the physical simulation material of the mechanism research of friction stir welding on the aluminum-copper dissimilar metals, the tool structure design parameters and welding process parameters for the relevant law of the material flow state in weld is explored by the physical simulation experiment, and the " joint performance-instantaneous thermal input" model is established due to the results of simulation test. And a friction stir welding process parameters design and process experiment in structure of 4 mm thick 1060 aluminum alloy and T2 copper dissimilar metals is guided by this model.The tool structure designs influence the liquid metal in the weld by force mostly is showed in the Physical simulation experiment results, the flow of the metal may changed for different designs of shoulder and stir may. Welding parameters are mainly related to the welding input heat during the process to influence the metal flow condition, the simulation results show that the offset of marking material change as a rising-stable-decline flow trend with the increasing of n, v and n/v this several parameters, and a" joint performance-instantaneous thermal input" model established according to the simulation results.Many similarities can be found in the physical simulation of dissimilar material and similar materials, as friction stir welding the dissimilar materials by offsetting the tool, the metal liquid is better.The best parameters are:stir speed of 800 r/min, welding speed is 100 mm/min, and tool-offset of 0.5 mm to aluminum. At this time of dissimilar metal welded joint of maximum tensile strength of 122.2 MPa, such as strength of the aluminum parent metal.The grain in the welding zone and thermal mechanical affecting zone of the joint are thinner by the tool stir mechanical effects, and the hardness of this zone increased to a certain extent, the grain in the thermal affecting zone has no changing of the copper’s quick cooling. Also the analysis of microstructure is suitable of the physical simulation. Electron microscope scanning is carried out on the joint, both brittle fracture and ductile fracture can be found in the joint,some intermetallic compounds such as CuAl, Cu3Al2 exist in the joint to weak the performance of the joint.