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Neupane FINAL 7 21 23 with cert.pdf (3.57 MB)

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Analysis of Linear Friction Welding of Dissimilar Metals: Aluminum and Copper with Zinc Interlayer

Neupane, Sandesh
http://rave.ohiolink.edu/etdc/view?acc_num=ysu169140896136818

Abstract Details

2023, Master of Science in Engineering, Youngstown State University, Department of Mechanical, Industrial and Manufacturing Engineering.
This thesis presents an analysis of linear friction welding of dissimilar metals, specifically aluminum and copper, with a zinc interlayer. The welding of aluminum and copper is significant for heat transfer and electrical applications, as these metals are commonly used. Traditional fusion welding methods are ineffective due to the metals' differing melting points, making solid-state joining processes like friction welding preferable. The main objective of this research is to address the challenges in welding copper and aluminum using linear friction welding and to improve the strength of the resulting weld. One major issue encountered during welding is the formation of brittle intermetallic compounds at the interface. To overcome this problem, an interlayer of zinc is used during the welding process. This study investigates the impact of two different thicknesses of the zinc interlayer, namely 0.07 mm and 0.2 mm. The welding process was conducted using a 20-ton vertical oscillator welding machine. The resulting welds were subjected to various analyses, including tensile tests, hardness tests, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). Successful welding was achieved both with and without the interlayer. There was no significant difference in the ultimate tensile strength (UTS) between the two interlayer thicknesses, but the UTS of the samples with interlayers showed a 28% increase compared to the samples without interlayers. The hardness at the junction without an interlayer was higher (180 HV) than the hardness with an interlayer (159 HV). SEM images revealed cracks in the welding regions without interlayers, indicating the formation of brittle intermetallic compounds at the junction. Thermal analysis was also performed to predict the temperature at the junction during welding, utilizing parameters such as frequency, amplitude, and time. The use of interlayer materials was found to enhance the tensile strength of the weld while reducing the hardness at the junction, suggesting a decrease in the formation of brittle intermetallic compounds. The thermal analysis successfully predicted the junction temperature. Further improvement could be achieved by optimizing parameters such as initial pressure, forge pressure, amplitude, and frequency. Additionally, comprehensive thermal analysis, considering heat conduction from the specimen to the tooling, can offer a deeper understanding of the welding process. Future experiments should incorporate the assumptions made in this study to further enhance the outcomes of copper-aluminum friction welding. These proposed enhancements pave the way for achieving stronger and more reliable joints in the future.
Jae Joong Ryu, PhD (Advisor)
C. Virgil Solomon, PhD (Committee Member)
Kyosung Choo, PhD (Committee Member)
85 p.
Materials Science; Mechanical Engineering
Linear Friction Welding; Dissimilar metals; Nanoindentation; Tensile test; Aluminum and Copper; Thermal Analysis

Recommended Citations

Citations

  • Neupane, S. (2023). Analysis of Linear Friction Welding of Dissimilar Metals: Aluminum and Copper with Zinc Interlayer [Master's thesis, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu169140896136818

    APA Style (7th edition)

  • Neupane, Sandesh. Analysis of Linear Friction Welding of Dissimilar Metals: Aluminum and Copper with Zinc Interlayer. 2023. Youngstown State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu169140896136818.

    MLA Style (8th edition)

  • Neupane, Sandesh. "Analysis of Linear Friction Welding of Dissimilar Metals: Aluminum and Copper with Zinc Interlayer." Master's thesis, Youngstown State University, 2023. http://rave.ohiolink.edu/etdc/view?acc_num=ysu169140896136818

    Chicago Manual of Style (17th edition)

ysu169140896136818
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This open access ETD is published by Youngstown State University and OhioLINK.
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