Influence of the eutectic interface on the fatigue behaviour of friction stir spot welds of aluminum with copper

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL International Journal of Fatigue Pub Date : 2025-01-27 DOI:10.1016/j.ijfatigue.2025.108834

E. Tognoli , K. Schricker , E. Bassoli , J.P. Bergmann

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Abstract

The development of hybrid bonds between copper and aluminum is being pursued for reasons of cost, functionality, and weight, particularly in the field of electromobility, to achieve near net-zero emissions. Joining aluminum to copper is a challenge, as interfacial intermetallic compounds have a negative impact on the strength, ductility, and electrical properties of the joint. The development of brittle intermetallic compounds can be limited by targeted temperature control, making solid-phase joining processes particularly suitable. In this article, the fatigue behaviour of friction stir spot welded joints of copper CW004A and aluminum alloy AA1050A with probeless tools is studied. A melt film forms between the metals and the axial force displaces this film laterally, creating an intermediate layer of eutectic and Al₂Cu in the joint area. The effect of this layer on the fatigue behaviour of the joint was investigated in this study. At high loads, failure occurs by a combination of Modes I and II with crack propagation in as well as around the bonding area, while at low loads only Mode I is observed. Typically, cracks origin at the spot outer diameter in aluminum, propagate at first in the laterally expelled melt and then through the aluminum sheet, causing unbuttoning.

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.