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<p>This paper presents the fabrication of larger-sized dissimilar pipe joints using direct drive friction welding processes and examines the interface characteristics of welded joints between electrolytic tough pitch copper (ETP-Cu) and the stainless steel alloy 304L (SS304L) within a pipe system. The study delved into the joining mechanisms and interface characterization under various friction welding conditions. The welded samples underwent examination through visual inspection, tensile testing, and microstructure characterization using optical and scanning electron microscopy, energy-dispersive x-ray spectroscopy, x-ray diffraction analysis, and microhardness assessment. The results acknowledge that excellent bonding was established between Cu–SS dissimilar metals. The dissimilar Cu–SS pipe joint achieved an impressive strength of 237.22&#xa0;MPa, representing nearly 94% of the strength of the Cu parent material. The majority of microstructure changes were reported on the Cu side such as full dynamic recrystallization zone, partial dynamic recrystallization zone, and heat-affected zone, where a little bit of variation was observed on the SS side like the HAZ region.</p><p>Furthermore, the examination of the reaction layer thickness in the Cu–SS joint indicated that a reduced reaction layer thickness enhances the joint's properties. Moreover, the Cu, Fe, and Si elements were identified at the interface region, where else Fe and Si were present on the Cu side away from the interface and created new phases of FeCu<sub>4</sub> and Cu<sub>9</sub>Si. Also, the new intermetallic compounds were noted in the interface and Cu side only.</p>

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Analysis of Mechanical and Microstructural Properties in Larger-Sized Electrolytic Tough Pitch Copper to SS304L Pipe Joints Produced by Friction Welding

  • 期刊论文

  • 发表日期：

    2025年2月26日

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  • Hardik D. Vyas,
  • Vishvesh Badheka

摘要

This paper presents the fabrication of larger-sized dissimilar pipe joints using direct drive friction welding processes and examines the interface characteristics of welded joints between electrolytic tough pitch copper (ETP-Cu) and the stainless steel alloy 304L (SS304L) within a pipe system. The study delved into the joining mechanisms and interface characterization under various friction welding conditions. The welded samples underwent examination through visual inspection, tensile testing, and microstructure characterization using optical and scanning electron microscopy, energy-dispersive x-ray spectroscopy, x-ray diffraction analysis, and microhardness assessment. The results acknowledge that excellent bonding was established between Cu–SS dissimilar metals. The dissimilar Cu–SS pipe joint achieved an impressive strength of 237.22 MPa, representing nearly 94% of the strength of the Cu parent material. The majority of microstructure changes were reported on the Cu side such as full dynamic recrystallization zone, partial dynamic recrystallization zone, and heat-affected zone, where a little bit of variation was observed on the SS side like the HAZ region.

Furthermore, the examination of the reaction layer thickness in the Cu–SS joint indicated that a reduced reaction layer thickness enhances the joint's properties. Moreover, the Cu, Fe, and Si elements were identified at the interface region, where else Fe and Si were present on the Cu side away from the interface and created new phases of FeCu4 and Cu9Si. Also, the new intermetallic compounds were noted in the interface and Cu side only.