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Materials 2019, 12(2), 205; https://doi.org/10.3390/ma12020205

Weibull Statistical Analysis of Strength Fluctuation for Failure Prediction and Structural Durability of Friction Stir Welded Al–Cu Dissimilar Joints Correlated to Metallurgical Bonded Characteristics

Department of Materials Science and Engineering, National Formosa University, No. 64, Wunhua Road, Huwei, Yunlin 63201, Taiwan
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Received: 14 December 2018 / Revised: 2 January 2019 / Accepted: 3 January 2019 / Published: 9 January 2019
(This article belongs to the Special Issue Welding, Joining and Coating of Metallic Materials)
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Abstract

In this paper, dissimilar Al–Cu joints of AA1050H/C1100-Cu, AA6061-T6/C1100-Cu, and AA1050H/C2600-brass are successfully welded by a friction stir welding (FSW) process. The aim of the present study is not only to examine the tensile strength, but also to investigate the reliability, durability, and failure behaviors of joints as correlated with the metallurgical bonded microstructures of varied Al–Cu joints. Experimental evidence confirms that good welding quality for an FSW Al–Cu dissimilar joint is obtained when pure Cu and brass plates are positioned at the advancing side. Cross-sectional microstructures reveal that the AA6061-T6/C1100-Cu joint exhibits an extensive metallurgical bonded region with significant onion rings in the welding zone, whereas the AA1050H/C2600-brass joint generally displays a clear mechanical kissing bonded boundary at the joint interface. Al2Cu, Al4Cu9, and γ-Cu5Zn8 are major intermetallic compounds (IMCs) that are formed within the metallurgical bonded welding zone. The Weibull model provides a statistical method for assessing the failure mechanism of FSW Al–Cu joints. Better welding reliability and tensile properties with ductile dimpled ruptures are obtained for the Al–Cu joints with a typical metallurgical bonded zone. However, a mechanical kissing bonded interface and thick interfacial IMCs result in the deterioration of tensile strength with a brittle fracture and a rapid increase in the failure probability of Al–Cu joints. View Full-Text
Keywords: friction stir welding; dissimilar joints; metallurgical bonding microstructure; the Weibull model; failure strength; engineering reliability friction stir welding; dissimilar joints; metallurgical bonding microstructure; the Weibull model; failure strength; engineering reliability
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Yang, C.-W.; Jiang, S.-J. Weibull Statistical Analysis of Strength Fluctuation for Failure Prediction and Structural Durability of Friction Stir Welded Al–Cu Dissimilar Joints Correlated to Metallurgical Bonded Characteristics. Materials 2019, 12, 205.

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