Experimental Analysis and Mathematical Model of FSW Parameter Effects on the Corrosion Rate of Al 6061-T6-Cu C11000 Joints

Abstract

Friction stir welding is characterized as an ecological and low-cost process in comparison to traditional welding techniques, and due to its application in the solid state, it is a feasible option for joining similar and/or dissimilar materials. The present investigation seeks to determine the effect of friction stir welding’s parameters on the corrosion resistance of an Al 6061-T6–Cu C11000 dissimilar joint, with mathematical analysis to validate the results. After the welding process, the samples were exposed to a NaCl solution in an electrochemical cell to determine the corrosion rate via potentiodynamic tests. Microstructural characterization revealed a laminar structure, composed of aluminum and copper, as well as copper particles and the formation of intermetallic compounds distributed in the weld zone. The potentiodynamic tests showed that the corrosion rate increased with the rotational and traverse speeds. The mathematical model quantifies the relationship between corrosion rate and rotational and traverse speeds.

Keywords

• friction stir welding
• aluminum
• copper
• corrosion resistance
• mathematical model
• correlation