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This article outlines the development and examination of the properties of an asymmetrical dissimilar metal joint produced using friction welding (FW). Friction welding involving dissimilar materials, specifically a 50 mm (length) × 45 mm (width) × 20-mm (thickness) electrolytic tough pitch copper (ETP-Cu) plate and a 12.5-mm-diameter SS304L rod, was carried out. The assessment of the asymmetrically welded components encompassed ultrasonic testing, high-pressure helium gas testing, leak testing, tensile testing, scanning electron microscopy, optical microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction analysis, hardness measurements, and elemental mapping via X-ray. Significantly, there was an observed increase in tensile strength, resulting in a joint efficiency of 86.50% compared to the ETP-Cu base material, following FW between an asymmetric ETP-Cu plate and SS304L rod. The study unveiled notable variations in the microstructure near the joint interface on the ETP-Cu material side. Intermetallic compounds, such as FeCu4 and Cu9Si phases, were detected within the reaction layer at the interface between ETP-Cu and SS304L, exhibiting a variable thickness ranging from 30 to 50 μm. [ABSTRACT FROM AUTHOR]

In the present work, the effect of the Sn addition (0.01 to 0.118) wt.% on the mechanical and microstructural properties of the copper base gray cast iron alloys has been investigated, and the fracture surface obtained from the tensile test was examined. The results show that the Sn alloying improved and refined the pearlitic structure in the alloys and causes graphite flakes to thin. The optimum pearlitic content in the microstructure is obtained with the 0.076 wt. % Sn-alloyed gray cast iron (T3). The T3 alloy also shows the optimum mechanical properties such as tensile strength of 380 MPa, hardness of 225 BHN, and impact strength of 3.2 Joules. The wear resistance is also high in the T3 alloy compared to all the samples. The fracture analysis shows that the Sn alloying causes more brittle fractures in the gray cast irons compared to the without alloying condition. [ABSTRACT FROM AUTHOR]

Ultrasonic welding has been widely used to bond dissimilar conductive wires, battery cell terminals in relay applications. In this paper, dissimilar metals, Al/Cu were joined using ultrasonic welding for conductive applications. Welding trials were carried out by varying three control parameters: (1) vibrational amplitude (40, 60, and 80 µm), (2) clamping pressure (1, 1.2, and 1.4 bar), (3) weld time (0.1, 0.2, and 0.3 s). Experimental trails were designed based on L Taguchi method. Interpretation of tensile strength and microhardness results revealed that the satisfactory weldments were obtained for higher welding energies when compared to low welding energies. From the microstructural analysis, the bond formation of metals and failure modes were studied. SEM and XRD images revealed the four major intermetallic compounds at the interface of joint; AlCu, AlCu, AlCu, and AlCu with resistivity values of 11.415, 8.027, 10.612, and 14.243 Ω-cm respectively. The resistivity values of intermetallic compounds observed in the joint was almost 5-6 times higher than the Al. [ABSTRACT FROM AUTHOR]