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The principles of the friction welding (FW) process of the two different non-ferrous metals, aluminum and copper, are presented in this paper. Considering that the bimetallic Al-Cu joints find applications in electrical engineering, as well as in other industrial fields, the basic characteristics and compatibility of these metals are discussed, along with the influence of various parameters on the properties of their friction welded joints. The experimental study involved rotation friction welding (RFW), which was used to weld aluminum and copper samples. The samples were monitored for shortening due to the applied deformation, as well as the size of the formed mushroom. Then, the central part of the welded joint was cut from the welded samples to determine the hardness and microstructure of the joint. At the end of the research, the possibility of applying software for the design of a numerical model for analysis of the possibility of joining aluminum and copper, with the same input parameters as those used in the experiment, was considered. The numerical simulation exhibited a high agreement with the experimental results.
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http://dx.doi.org/10.3390/ma18091932 | DOI Listing |
Materials (Basel)
August 2025
College of Mechanical and Electrical Engineering, Huangshan University, Huangshan 245041, China.
In this study, under varying PDSP (plunging depths of stirring pin) and process parameters, refill friction stir spot welding tests were performed on 6061-T6 aluminum alloy, relying on a stirring tool with a 12 mm sleeve diameter and an 8 mm stirring pin diameter. The results manifested the internal defects in the weld zone when PDSP was 0, notwithstanding the alterations in process parameters. However, these flaws disappeared when PDSP was 0.
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August 2025
E.O. Paton Education and Research Institute of Materials Science and Welding, National Technical University of Ukraine 'Igor Sikorsky Kyiv Polytechnic Institute', 37, Beresteiskyi Ave., UA-03056 Kyiv, Ukraine.
A friction composite material which contains cellulose fiber, carbon fiber, wollastonite, graphite, and resin for use in oil-cooled friction units, hydromechanical boxes, and couplings was developed. The fabrication technique includes the formation of a paper layer based on the mixture of stated fibers via a wet-laid process, impregnation of the layer with phenolic resin, and hot pressing onto a steel carrier. The infrared spectra of the polymeric base (phenolic resin) were studied by solvent extraction.
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August 2025
Department of Mechanical Engineering, Manipal University Jaipur, Jaipur, 303007, Rajasthan, India.
The present work aims to optimize the process parameters of friction stir welding (FSW) to improve the mechanical behavior of AISI 1018 carbon steel joints. The study explores the influence of welding speed, tool rotational speed, and shoulder diameter on ultimate tensile strength (UTS), percentage elongation (PE), percentage reduction in area (RA), and impact energy (IE). To achieve this, both single-response and multi-response optimization methods were applied.
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July 2025
College of Materials Science and Engineering, Hunan University, Changsha 410082, China.
Aluminum matrix composites provide an ideal solution for lightweight brake disks, but conventional casting processes are prone to crack initiation due to inhomogeneous reinforcement dispersion, gas porosity, and inadequate toughness. To break the conventional trade-off between high wear resistance and low toughness of brake disks, this study fabricated a bimetallic structure of SiC/Al-Fe-V-Si aluminum matrix composite and cast ZL101 alloy using friction stir lap welding (FSLW). Then, the microstructural evolution, mechanical properties, and tribological behavior of the FSLW joints were studied by XRD, SEM, TEM, tensile testing, and tribological tests.
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July 2025
Centre for Assessment of Structures and Materials Under Extreme Conditions (CASMEC), Department of Mechanical and Aerospace Engineering, Brunel University London, London UB8 3PH, UK.
This paper describes the development of a new hybrid composite for the metal joints of aluminium and glass fibre composite adherents. The aluminium adherend is manufactured using friction stir-formed studs that are inserted into the composite adherend in the through-thickness direction during the composite manufacturing process, where the dry fibres are displaced to accommodate the studs before the resin infusion process. The materials used were AA6082-T6 aluminium and plain-woven E-glass fabric reinforced epoxy, with primary applications in naval vessels.
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