Unveiling non-equilibrium metallurgical phases in dissimilar Al-Cu joints processed by vaporizing foil actuator welding

Wang, Kaifeng; Shang, Shun-Li; Wang, Yuxiang; Vivek, Anupam; Daehn, Glenn; Liu, Zi-Kui; Li, Jingjing

doi:10.1016/j.matdes.2019.108306

Title: Unveiling non-equilibrium metallurgical phases in dissimilar Al-Cu joints processed by vaporizing foil actuator welding

Journal Article · Wed Jan 01 00:00:00 EST 2020 · Materials & Design

DOI:https://doi.org/10.1016/j.matdes.2019.108306· OSTI ID:1574029

Wang, Kaifeng; Shang, Shun-Li; Wang, Yuxiang; Vivek, Anupam; Daehn, Glenn; Liu, Zi-Kui; Li, Jingjing

An integrated experimental and computational approach has been adopted to investigate the formation mechanism of intermetallic compounds (IMCs) in dissimilar Al-Cu joints processed by vaporizing foil actuator welding (VFAW). Aiming to understand the formation of IMCs and their transition, the present work employed firstprinciples calculations of thermodynamic properties as a function of temperature and pressure together with diffusivities of Al and Cu from the literature. Agreeing with experimental observations, the predicted IMC formation sequence in the low-energy welding region is as follows. θ-Al₂Cu forms first due to the fast diffusivity of Cu in the Al-matrix. θ-Al₂Cu then transforms to η₂-AlCu because of the fast diffusivities of Al/Cu in θ-Al₂Cu. In the highenergy welding region, the stable γ₁-Al₄Cu₉ and the metastable θ’’-Al₃Cu are also formed in addition to the aforementioned θ-Al2Cu and η₂-AlCu. η₂-AlCu and considerable γ₁-Al₄Cu₉ are the major phases in the high-energy welding region. The present approach, combining experiments and calculations, is proven to be a practical way to understand non-equilibrium metallurgical processes, as demonstrated through the study of VFAW Al-Cu joints.

View Journal Article

Cite

Export

Save

Research Organization:: Univ. of Michigan, Ann Arbor, MI (United States); Univ. of California, Oakland, CA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0008456; AC02-05CH11231

OSTI ID:: 1574029

Alternate ID(s):: OSTI ID: 1799514

Journal Information:: Materials & Design, Journal Name: Materials & Design Vol. 186 Journal Issue: C; ISSN 0264-1275

Publisher:: ElsevierCopyright Statement

Country of Publication:: United Kingdom

Language:: English

Citation Metrics:

Cited by: 15 works

Citation information provided by
Web of Science

References (36)

Microstructural and mechanical properties of friction stir welded aluminum/copper lap joints Abdollah-Zadeh, A.; Saeid, T.; Sazgari, B. Journal of Alloys and Compounds, Vol. 460, Issue 1-2 https://doi.org/10.1016/j.jallcom.2007.06.009	journal	July 2008
Generalized Gradient Approximation Made Simple Perdew, John P.; Burke, Kieron; Ernzerhof, Matthias Physical Review Letters, Vol. 77, Issue 18, p. 3865-3868 https://doi.org/10.1103/PhysRevLett.77.3865	journal	October 1996
Microstructure, welding mechanism, and failure of Al/Cu ultrasonic welds Wu, Xin; Liu, Teng; Cai, Wayne Journal of Manufacturing Processes, Vol. 20 https://doi.org/10.1016/j.jmapro.2015.06.002	journal	October 2015
First-principles thermodynamics from phonon and Debye model: Application to Ni and Ni3Al Shang, Shun-Li; Wang, Yi; Kim, DongEung Computational Materials Science, Vol. 47, Issue 4 https://doi.org/10.1016/j.commatsci.2009.12.006	journal	February 2010
Computational investigation of constitutional liquation in Al–Cu alloys Jiang, Chao; Liu, Zi-Kui Acta Materialia, Vol. 51, Issue 15 https://doi.org/10.1016/S1359-6454(03)00280-5	journal	September 2003
Laser impact welding of aluminum to brass Wang, Xiao; Shao, Meng; Jin, Hao Journal of Materials Processing Technology, Vol. 269 https://doi.org/10.1016/j.jmatprotec.2019.02.005	journal	July 2019
Vaporizing foil actuator: A tool for collision welding Vivek, A.; Hansen, S. R.; Liu, B. C. Journal of Materials Processing Technology, Vol. 213, Issue 12, p. 2304-2311 https://doi.org/10.1016/j.jmatprotec.2013.07.006	journal	December 2013
The Open Quantum Materials Database (OQMD): assessing the accuracy of DFT formation energies Kirklin, Scott; Saal, James E.; Meredig, Bryce npj Computational Materials, Vol. 1, Issue 1 https://doi.org/10.1038/npjcompumats.2015.10	journal	December 2015
Thermodynamic assessment of the Al–Cu–Zn system, part II: Al–Cu binary system Liang, Song-Mao; Schmid-Fetzer, Rainer Calphad, Vol. 51 https://doi.org/10.1016/j.calphad.2015.10.004	journal	December 2015
In situ metallic porous structure formation due to ultra high heating and cooling rates during an electromagnetic pulse welding Sapanathan, T.; Raoelison, R. N.; Buiron, N. Scripta Materialia, Vol. 128 https://doi.org/10.1016/j.scriptamat.2016.09.030	journal	February 2017
Microstructural evolution in the friction stir welded 6061 aluminum alloy (T6-temper condition) to copper Ouyang, Jiahu; Yarrapareddy, Eswar; Kovacevic, Radovan Journal of Materials Processing Technology, Vol. 172, Issue 1 https://doi.org/10.1016/j.jmatprotec.2005.09.013	journal	February 2006
Efficient iterative schemes for ab initio total-energy calculations using a plane-wave basis set Kresse, G.; Furthmüller, J. Physical Review B, Vol. 54, Issue 16, p. 11169-11186 https://doi.org/10.1103/PhysRevB.54.11169	journal	October 1996
From ultrasoft pseudopotentials to the projector augmented-wave method Kresse, G.; Joubert, D. Physical Review B, Vol. 59, Issue 3, p. 1758-1775 https://doi.org/10.1103/PhysRevB.59.1758	journal	January 1999
Microstructure evolution and mechanical properties of Cu–Al joints by ultrasonic welding Yang, J. W.; Cao, B.; He, X. C. Science and Technology of Welding and Joining, Vol. 19, Issue 6 https://doi.org/10.1179/1362171814Y.0000000218	journal	May 2014
Ternary rare-earth aluminum systems with copper: A review and a contribution to their assessment Riani, P.; Arrighi, L.; Marazza, R. Journal of Phase Equilibria and Diffusion, Vol. 25, Issue 1 https://doi.org/10.1007/s11669-004-0169-7	journal	February 2004
Precipitates and intermetallic phases in precipitation hardening Al–Cu–Mg–(Li) based alloys Wang, S. C.; Starink, M. J. International Materials Reviews, Vol. 50, Issue 4 https://doi.org/10.1179/174328005X14357	journal	August 2005
Commentary: The Materials Project: A materials genome approach to accelerating materials innovation Jain, Anubhav; Ong, Shyue Ping; Hautier, Geoffroy APL Materials, Vol. 1, Issue 1 https://doi.org/10.1063/1.4812323	journal	July 2013
Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al–Cu joints Xue, P.; Ni, D. R.; Wang, D. Materials Science and Engineering: A, Vol. 528, Issue 13-14 https://doi.org/10.1016/j.msea.2011.02.067	journal	May 2011
Ideal Pure Shear Strength of Aluminum and Copper Ogata, S. Science, Vol. 298, Issue 5594 https://doi.org/10.1126/science.1076652	journal	October 2002
First-principles calculations of lattice dynamics and thermal properties of polar solids Wang, Yi; Shang, Shun-Li; Fang, Huazhi npj Computational Materials, Vol. 2, Issue 1 https://doi.org/10.1038/npjcompumats.2016.6	journal	May 2016
Single‐crystal elastic constants of Al ₂ Cu Eshelman, F. R.; Smith, J. F. Journal of Applied Physics, Vol. 49, Issue 6 https://doi.org/10.1063/1.325278	journal	June 1978
Application of high velocity impact welding at varied different length scales Zhang, Yuan; Babu, Sudarsanam Suresh; Prothe, Curtis Journal of Materials Processing Technology, Vol. 211, Issue 5 https://doi.org/10.1016/j.jmatprotec.2010.01.001	journal	May 2011
Phase equilibria in the Cu-rich portion of the Cu–Al binary system Liu, X. J.; Ohnuma, I.; Kainuma, R. Journal of Alloys and Compounds, Vol. 264, Issue 1-2 https://doi.org/10.1016/S0925-8388(97)00235-1	journal	January 1998
Thermodynamic properties of Al, Ni, NiAl, and Ni3Al from first-principles calculations Wang, Y.; Liu, Z. -K.; Chen, L. -Q. Acta Materialia, Vol. 52, Issue 9 https://doi.org/10.1016/j.actamat.2004.02.014	journal	May 2004
Entropy favored ordering: Phase stability of Ni3Pt revisited by first-principles Shang, Shun-Li; Wang, Yi; Du, Yong Intermetallics, Vol. 18, Issue 5 https://doi.org/10.1016/j.intermet.2010.01.011	journal	May 2010
Effect of the flyer material on the interface phenomena in aluminium and copper explosive welds Carvalho, G. H. S. F. L.; Mendes, R.; Leal, R. M. Materials & Design, Vol. 122 https://doi.org/10.1016/j.matdes.2017.02.087	journal	May 2017
Linear friction welding of aluminium to copper Bhamji, I.; Moat, R. J.; Preuss, M. Science and Technology of Welding and Joining, Vol. 17, Issue 4 https://doi.org/10.1179/1362171812Y.0000000010	journal	May 2012
High-precision sampling for Brillouin-zone integration in metals Methfessel, M.; Paxton, A. T. Physical Review B, Vol. 40, Issue 6 https://doi.org/10.1103/PhysRevB.40.3616	journal	August 1989
Magnetic pulse welding: Interface of Al/Cu joint and investigation of intermetallic formation effect on the weld features Raoelison, R. N.; Racine, D.; Zhang, Z. Journal of Manufacturing Processes, Vol. 16, Issue 4 https://doi.org/10.1016/j.jmapro.2014.05.002	journal	October 2014
Weldability and mechanical properties of dissimilar aluminum–copper lap joints made by friction stir welding Saeid, T.; Abdollah-zadeh, A.; Sazgari, B. Journal of Alloys and Compounds, Vol. 490, Issue 1-2 https://doi.org/10.1016/j.jallcom.2009.10.127	journal	February 2010
Investigation of Interfacial Layer for Ultrasonic Spot Welded Aluminum to Copper Joints Zhang, Zijiao; Wang, Kaifeng; Li, Jingjing Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/s41598-017-12164-2	journal	October 2017
Improved tetrahedron method for Brillouin-zone integrations Blöchl, Peter E.; Jepsen, O.; Andersen, O. K. Physical Review B, Vol. 49, Issue 23 https://doi.org/10.1103/PhysRevB.49.16223	journal	June 1994
Growth rate of intermetallic compounds in Al/Cu bimetal produced by cold roll welding process Abbasi, M.; Karimi Taheri, A.; Salehi, M. T. Journal of Alloys and Compounds, Vol. 319, Issue 1-2 https://doi.org/10.1016/S0925-8388(01)00872-6	journal	April 2001
YPHON: A package for calculating phonons of polar materials Wang, Yi; Chen, Long-Qing; Liu, Zi-Kui Computer Physics Communications, Vol. 185, Issue 11 https://doi.org/10.1016/j.cpc.2014.06.023	journal	November 2014
The aluminium-copper system Murray, J. L. International Materials Reviews, Vol. 30, Issue 1 https://doi.org/10.1179/imr.1985.30.1.211	journal	January 1985
Entropically Favored Ordering: The Metallurgy of ${Al}_{2} Cu$ Revisited Wolverton, C.; Ozoliņš, V. Physical Review Letters, Vol. 86, Issue 24 https://doi.org/10.1103/PhysRevLett.86.5518	journal	June 2001

Similar Records

Forming mechanism of equilibrium and non-equilibrium metallurgical phases in dissimilar aluminum/steel (Al–Fe) joints

Journal Article · Mon Dec 20 00:00:00 EST 2021 · Scientific Reports · OSTI ID:1574029

Shang, Shun-Li; Sun, Hui; Pan, Bo; +5 more

Evaluation of Zn-rich coatings for IMC reaction control in aluminum-magnesium dissimilar welds

Journal Article · Tue May 15 00:00:00 EDT 2018 · Materials Characterization · OSTI ID:1574029

Wang, Yin

The significance of intermetallic compounds formed during interdiffusion in aluminum and magnesium dissimilar welds

Journal Article · Fri Dec 15 00:00:00 EST 2017 · Materials Characterization · OSTI ID:1574029

Wang, Yin

Related Subjects

36 MATERIALS SCIENCE
Materials Science
Vaporizing foil actuator welding (VFAW)
Al-Cu intermetallic compounds
Thermodynamic properties
Diffusion
First-principles and phonon calculations

Title: Unveiling non-equilibrium metallurgical phases in dissimilar Al-Cu joints processed by vaporizing foil actuator welding

Citation Formats

References (36)

Similar Records

Related Subjects