Advances in Social Science, Education and Humanities Research, volume 576

Proceedings of the 2nd International Conference on Science, Technology, and Modern Society (ICSTMS 2020)

The Effect of Micro Friction Stir Spot Welding

Parameters to Cu-Al Dissimilar Joint

Suwarsono* Hakam Muzakki, Ikrom Millaily, Ahmadi

University of Muhammadiyah Malang Universitas Trunojoyo Madura
Malang, Indonesia Bangkalan, Indonesia
*suwarsono@umm.ac.id

Abstract—Dissimilar welding or joining dissimilar metals problems in dissimilar welding. Thinness of base metals is as
using welding process, Micro welding or welding process for also big problem for welding process not only for friction but
joining metals less than 1 mm, have unique problem difference of also another. Some studies about mechanical properties of weld
thermal properties from metals lead to melting processes and joint have been studied by some researchers. Mechanical
thin of metal affected easy to filed (hole). Welding parameters properties of Aluminum to Magnesium joint with Sn-coated
affected to weld join performance, this study discussed effect of steel as interlayer welded by Resistance spot welding were
Micro Friction Stir Spot Welding (Micro-FSSW) parameters to studied by M. Sun et al. [6]. Lacki and Niemiro studied the
performance of both thin plate of 0.5mm of Copper with 0.5 of
strength on beam made of titanium grade 2 and 5 welded by
aluminium which were joined by welding process. Tensile test
Resistance spot welding [7]. Xiao-yong WANG et al also
was used as the mechanical performance analysis. Micro-FSSW
succeeds to joint thin Cu and Al plate. Weld joint welded by
studied mechanical properties of magnesium to steel used
shoulder diameters 6 mm, welding force 50 kgf, and 3000 rpm of Metal Inert Gas (MIG) welding [8]. Mechanical and
rotation speed (constant), and welding time 60 sec could be microstructure properties of a new alloy join of Al-Zn-Mg-Cu
achieved 401.7 N of maximum load. welded by TIG and Laser were compared by Liang Zhang et al
[9]. I. Tomashchuk et al studied the evolution of mechanical
Keywords—micro friction stir spot welding, dissimilar metals, and microstructure properties from the titanium alloy and
copper-aluminium, mechanical properties stainless steel with copper as interlayer welded by an electron
beam welding [10]. M.H. Razmpoosh et al also studied the
I. INTRODUCTION mechanical properties and microstructural evolution from
TWIP steel joint welded by Resistance spot welding [11].
Each materials has advantages mechanical properties which
can be applied for a construction or a device, however Micro welding has been also studied by researchers such as
difference thermal properties is a problem of welding process Mehlmann et al developed laser micro welding for joining thin
[1]. Micro Friction Stir Welding (Micro FSW) is a welding cupper of 300 µm, Ultrasonic welding was used to create
process for base metals which has thickness less than 1mm aluminum with copper bonding [12]. Kondapalli Siva Prasad et
using Friction Stir Welding[2]. Micro Welding or welding al analyzed weld performance from Austenitic Stainless Steels
process for plates with thickness less than 1mm can be applied joint of Micro plasma arch welding, the plate thickness of 0.25
to light construction for supporting low weight construction mm. The compared welding quality of some type AISI 3xx,
such as battery and fuel cell. Production high efficiency and AISI 304 has highest hardness and tensile strength [13]. Hu
low weight construction as highlight issues for researchers and Zhang et al analyzed of high frequency of radiation of micro
engineer to improve a production of hybrid structures [2]. plasma welding, SS 304 with thickness 0.1 mm as specimen
Many researchers studied dissimilar FSW to encourage hybrid [14]. Baskoro et all studied mechanical properties and
construction structures. microstructure from dissimilar welding of SS301-Al1100
micro RSW joints, the thickness of both base metals is 200 µm
Some researchers studied dissimilar welding such as and 400 µm [15].
Tianhao Wang et all studied mechanical properties and
interfacial both metals a magnesium-steel joint welded by Manickam et all had been studied Friction Stir Spot
Friction-stir Assisted Scribe Technique [3]. Elnabi et all Welding (FSSW) AA-Cu Alloy [16]. AA-Cu lap joint of
studied a nugget of dissimilar Fe-Al friction stir weld, they Micro-FSSW with Cu on the AA sheet has been studied in this
evaluated the intermetallic compound formation. Intermetallic discussion. Few researchers discussed micro dissimilar
compound developed tend to brittle [4]. Gagliardi et all joined welding, dissimilar welding has differences thermal properties,
metallic and Polymeric using Friction Stir Forming [5]. it is the problem for welding process and thinness of base
Differences materials lead to intermetallic compound and also metals is also problems in micro welding. In this study
thermal resistance effected to melting condition, these are discussed performance of a Cu-Al micro-weld joint. This study
discussed the performance of AA-Cu micro-FSSW joints.

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 Advances in Social Science, Education and Humanities Research, volume 576

II. MATERIAL AND METHODS 27 specimens were measured load maximum represented
Cupper sheet was cut based on dimension standard of the mechanical properties from weld nugget performance.
American Welding Society (AWS), 19 mm of wide, and 76 Tensile test process for three specimen of each combination
mm of length because of the thickness from plate 0.5 mm[17]. welding parameters, each tested specimen was given such as
The thickness of Copper and Aluminum sheet are 0.5 mm. SD4F30S1, SD4F30S2, SD4F30S3. Hydraulic Universal
Each piece of both metals was washed by pure alcohol. Both Testing Machine of UH-500kNI Series from SHIMADZU was
base metal types were cut shown in Figure 1. used for tensile test. The tensile test machine was shown by
Figure 4.

Fig. 1. A piece of copper and a piece of aluminum.

Both metals were welded by FSSW lap joint with copper

sheet on aluminum sheet. Welding position from base metals
was shown by Figure 2. Circle on the cupper represented that
Up-side of copper sheet was plunged by shoulder.

Fig. 2. Overlap of both based metals with a piece of copper above of an Fig. 4. A specimen installed and tensile test machine.
aluminium.
Base metal loss each other because of resistance from weld
Dimension of shoulder in this study has pin inter center, the nugget lower than load force. Speed load was 0.5 mm/min used
diameter of shoulders is 4mm, 6mm, and 8mm. Long and 10 N of sensitivity.
diameters of pin were same or constant. Electric motor was
used to rotate the shoulders with rotation speed of shoulder III. RESULTS AND ANALYSIS
constant 3000 rpm, and shoulder forces were 30 kgf, 40 kgf,
and 50 kgf (Table 1). Specimens welded by each combination welding parameter,
third of repetition have difference maximum load value.
Welding parameters with 4mm of Shoulder Dimension, 30 kgf
TABLE I. WELDING PARAMETERS AND VALUE OF LEVELING of Welding Force, 60 Sec of Welding Time (constant), and 300
Solder Pressure / Rotations Welding Specimen rpm of Rotation Speed (constant) succeed to joint Cu-Al
Diameters Force (kgf) F Speed (rpm) Time (Sec) Code however each repetition achieved maximum load was
(mm) S difference, 401.6 N of SD6F50S3 that represent Shoulder
4 30 3000 60 SD4F30Sx Diameter is 6mm, Welding Force is 50 kgf, and Second of
6 40 3000 60 SD6F40Sx repetition 2, 272.6 N of SD6F40S1, and 292 N of SD6F40S3.
8 50 3000 60 SD8F60Sx
The highest of maximum load achieved by weld joint from
leveling of shoulder diameter were shown in Figure 5.
Each combination of welding parameters was used to joint
5 specimens, 3 specimens used to tensile tested, and 1
specimen used macrostructure analysis. A welded specimen
was shown in Figure 3.

Fig. 3. Both pieces of metals welded.

Fig. 5. The highest of maximum load from each shoulder diameter leveling.

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 Advances in Social Science, Education and Humanities Research, volume 576

IV. CONCLUSION with Sn-coated steel interlayer," Materials and Design, vol. 91, pp. 331-
339, 2016.
A weld joint joined by shoulder diameters 6 mm, welding [7] P. Lacki and J. Niemiro, "Strength evaluation of the beam made of the
force 50 kgf, and S2 or second repetition could be achieved titanium sheets Grade 2 and Grade 5 welded by Resistance Spot
401.7 N of maximum loading from tensile test. Shoulder used Welding," Composite Structures vol. 159, pp. 538-547, 2017
by diameter 8 mm could only achieve 176.8 N as the highest of [8] X.-y. WANG, D.-q. SUN, S.-q. YIN, and D.-y. LIU, "Microstructures
the diameter 8 mm. A joint welded by shoulder diameter 4 mm and mechanical properties of metal inert-gas arc welded Mg−steel
with welding force 50 kgf can be resistance 268.8 N of load. dissimilar joints," Trans. Nonferrous Met. Soc. China vol. 25, p.
2533−2542, 2015.
[9] L. Zhang, X. Li, Z. Nie, H. Huang, and L. Niu, "Comparison of
ACKNOWLEDGMENTS microstructure andmechanical properties of TIGand laser welding joints
of a new Al–Zn–Mg–Cu alloy," Materials and Design, vol. 92, pp. 880-
The authors would like to thank the encouragement from 887, 2016.
colleagues, and financial support from DPPM University of [10] I. Tomashchuk, P. Sallamand, N. Belyavina, and M. Pilloz, "Evolution
Muhammadiyah Malang and LPPM Universitas Trunojoyo of microstructures and mechanical properties during dissimilar electron
Madura. beam welding of titanium alloy to stainless steel via copper interlayer,"
Materials Science & Engineering A, vol. 585, pp. 114–122, 31 July 2013
2013.
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