Skip to main content
SpringerLink
Log in

Achievement of defect-free and high-properties multilayer copper foils flexible connection by friction stir welding

  • Research Paper
  • Published:
Welding in the World Aims and scope Submit manuscript

Abstract

The connection of new energy vehicle batteries often involves a copper flexible connection. In this experiment, Friction stir welding (FSW) of multilayer copper foils was proposed for the research of copper flexible connection. It studies the correlation between microhardness profiles, conductivity test data, welding morphology, and process parameters. When the traverse speed (\(v\)) is unchanged at 80 mm/min, and the rotation speed (ω) increases from 300,600,900,1200, to 1500 rpm, the copper color of the weld gradually changes from yellow to purple-green. Elongated grains were processed into fine equiaxed and recrystallized grains by FSW. After 900 rpm to 80 mm/min FSW of multilayer copper foils to have a better morphology, the hardness of the (nugget zone) NZ increases by about 23 HV, and the conductivity decreases by about 22 IACS. After FSW, the hardness value is the opposite trend of ω/\(v\) changes, and the conductivity value is the similar change trend of ω/\(v\) changes in the NZ.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

Data availability

Data openly available in a public repository.

References

  1. Ye Q, Li A, Fu Q (2021) Effects of preparation methods for Cu foil on the electric-explosion properties. Propellants Explos Pyrotech 46:555–562. https://doi.org/10.1002/prep.202000156

    Article  CAS  Google Scholar 

  2. Zhang X, Wei L, Xu G (2019) Connection status research of the resistance spot welding joint based on a rectangular terminal electrode. Metal 9:659. https://doi.org/10.3390/met9060659

    Article  CAS  Google Scholar 

  3. Nothdurft S, Seffer O, Hermsdorf J (2022) Investigations on laser beam welding of thin foils of copper and aluminum regarding weld seam quality using different laser beam sources. J Laser Appl 34:042–11. https://doi.org/10.2351/7.0000777

    Article  CAS  Google Scholar 

  4. Zhan X, Meng Y, Gu D (2019) A comparative study between pulsed metal inert gas welding and continuous metal inert gas welding on thin Invar alloy. Proc Inst Mech Eng, Part B: J Eng Manuf 233:527–538. https://doi.org/10.1177/0954405417748186

    Article  CAS  Google Scholar 

  5. Shin S, Nam S, Yu J (2021) Ultrasonic metal welding of multilayered copper foils to nickel-plated copper sheet in lithium-ion battery cell. Metals 11:11–95. https://doi.org/10.3390/met11081195

    Article  CAS  Google Scholar 

  6. Machniewicz T, Nosal P, Korbel A (2020) Effect of FSW traverse speed on mechanical properties of copper plate joints. Materials 13:19–37. https://doi.org/10.3390/ma13081937

    Article  CAS  Google Scholar 

  7. Teimurnezhad J, Pashazadeh H, Masumi A (2016) Effect of shoulder plunge depth on the weld morphology, macrograph and microstructure of copper FSW joints(Article). J Manuf Process 22:254–259. https://doi.org/10.1016/j.jmapro.2016.04.001

    Article  Google Scholar 

  8. Wang YD, Zhu SZ, Xie GM (2021) Realising equal-strength welding with good conductivity in Cu–Cr–Zr alloy via friction stir welding. Sci Technol Weld Joining 26:448–454. https://doi.org/10.1080/13621718.2021.1935151

    Article  CAS  Google Scholar 

  9. Panchal M, Patel D, Vyas H (2020) Ultra-thin friction stir welding on aluminum alloy. Mater Today: Proc 26:2888–2894. https://doi.org/10.1016/j.matpr.2020.02.597

    Article  CAS  Google Scholar 

  10. Guan W, Shen Y, Yan Y (2018) Fabrication of ultra-thin copper foil pressure welding using FSW equipment. J Mater Process Technol 251:343–349. https://doi.org/10.1016/j.jmatprotec.2017.08.022

    Article  Google Scholar 

  11. Gera D, Fu B, Suhuddin UFHR (2021) Microstructure, mechanical and functional properties of refill friction stir spot welds on multilayered aluminum foils for battery application. J Mater Res Technol 13:2272–2286. https://doi.org/10.1016/j.jmrt.2021.06.017

    Article  CAS  Google Scholar 

  12. Ghosh M, Kumar K, Mishra RS (2011) Friction stir lap welded advanced high strength steels: microstructure and mechanical properties. Mater Sci Eng Struct Mater: Prop Misrostructure Process 528:8111–8119. https://doi.org/10.1016/j.msea.2011.06.087

    Article  CAS  Google Scholar 

  13. Xie G, Cui H, Luo Z (2017) Asymmetric distribution of microstructure and impact toughness in stir zone during friction stir processed a high strength pipeline steel. Mater Sci Eng, A 704:401–411. https://doi.org/10.1016/j.msea.2017.08.008

    Article  CAS  Google Scholar 

  14. Mehta KP, Badheka VJ (2017) Influence of tool pin design on properties of dissimilar copper to aluminum friction stir welding. Trans Nonferrous Metals Soc China 27:36–54. https://doi.org/10.1016/S1003-6326(17)60005-0

    Article  CAS  Google Scholar 

  15. Pradeep S, Jain VKS, Muthukumaran S (2021) Microstructure and texture evolution during multi-pass friction stir processed AA5083. Mater Lett 288:129–382. https://doi.org/10.1016/j.matlet.2021.129382

    Article  CAS  Google Scholar 

  16. Hasan AF (2019) CFD modelling of friction stir welding (FSW) process of AZ31 magnesium alloy using volume of fluid method. J Market Res 8:1819–1827. https://doi.org/10.1016/j.jmrt.2018.11.016

    Article  CAS  Google Scholar 

  17. Sakthivel T, Mukhopadhyay J (2007) Microstructure and mechanical properties of friction stir welded copper. J Mater Sci 42:8126–8129. https://doi.org/10.1007/s10853-007-1666-y

    Article  CAS  Google Scholar 

  18. Carlton CE, Ferreira PJ (2007) What is behind the inverse Hall-Petch effect in nanocrystalline materials? Acta Mater 55:3749–3756. https://doi.org/10.1016/j.actamat.2007.02.021

    Article  CAS  Google Scholar 

  19. Velichko OV, Ivanov SY, Karkhin VA (2016) Structure and properties of thick-walled joints of alloy 1570S prepared by friction stir weldin. Met Sci Heat Treat 58:346–351. https://doi.org/10.1007/s11041-016-0015-7

    Article  CAS  Google Scholar 

  20. Hwang Y, Fan P, Lin C (2010) Experimental study on friction stir welding of copper metals. J Mater Process Technol 210:1667–1672. https://doi.org/10.1016/j.jmatprotec.2010.05.019

    Article  CAS  Google Scholar 

  21. Naqibi MF, Elyasi M, Aval HJ (2021) Theoretical and experimental studies on fabrication of two-layer aluminum−copper pipe by friction stir additive manufacturing. Trans Nonferrous Met Soc China 31:3643–3658. https://doi.org/10.1016/s1003-6326(21)65754-0

    Article  CAS  Google Scholar 

  22. Muhammad NA, Wu C (2020) Evaluation of capabilities of ultrasonic vibration on the surface, electrical and mechanical behaviours of aluminium to copper dissimilar friction stir welds. Int J Mech Sci 183:105–784. https://doi.org/10.1016/j.ijmecsci.2020.105784

    Article  Google Scholar 

  23. Abdollah-Zadeh A, Saeid T, Sazgari B (2008) Microstructural and mechanical properties of friction stir welded aluminum/copper lap joints. J Alloy Compd 460:535–538. https://doi.org/10.1016/j.jallcom.2007.06.009

    Article  CAS  Google Scholar 

  24. Wang YD, Xue P, Liu FC (2023) Influence of processing innovations on joint strength improvements in friction stir welded high strength copper alloys. Mater Sci Eng, A 872:144–983. https://doi.org/10.1016/j.msea.2023.144983

    Article  CAS  Google Scholar 

  25. Miyajima Y, Komatsu SY, Mitsuhara M (2010) Change in electrical resistivity of commercial purity aluminum severely plastic deformed. Phil Mag 90:4475–4488. https://doi.org/10.1080/14786435.2010.510453

    Article  CAS  Google Scholar 

  26. Leal RM, Galvao I, Loureiro A (2015) Effect of friction stir processing parameters on the microstructural and electrical properties of copper. Int J Adv Manuf Technol 80:1655–1663. https://doi.org/10.1007/s00170-015-7141-z

    Article  Google Scholar 

  27. Lipińska M, Bazarnik P, Lewandowska M (2016) The influence of severe plastic deformation processes on electrical conductivity of commercially pure aluminium and 5483 aluminium allo. Arch Civ Mech Eng 16:717–723. https://doi.org/10.1016/j.acme.2016.04.013

    Article  Google Scholar 

Download references

Funding

This study was funded by Jiangxi Provincial Natural Science Foundation Project (20212BAB214025); Jiangxi Provincial Department of Education Science and Technology Research Project (GJJ170501); Jiangxi Provincial Department of Education Science and Technology Project (GJJ210882); Ganzhou Science and Technology Plan Project Science and Technology Innovation Talent Program; Ganzhou Science and Technology Plan Project; and Jiangxi University of Science and Technology Ph.D. Foundation Funded Project (JXXJBS16001).

Author information

Authors and Affiliations

  1. Faculty of Materials Metallurgy and Chemistry, Jiangxi University of Science and Technology, Ganzhou, 341000, China

    Zihang Li, Yongfang Deng, Liang Hu & Yutao Zhou

  2. Jiangxi Provincial Key Laboratory of Maglev Technology, Ganzhou, 341000, China

    Zihang Li, Yongfang Deng, Jincheng Zeng, Liang Hu & Yutao Zhou

  3. National Rare Earth Functional Material Innovation Center, Ganzhou, 341000, China

    Yongfang Deng

  4. School of Electrical Engineering and Automation, Jiangxi University of Science Technology, Ganzhou, 341000, China

    Jincheng Zeng

  5. Jiangxi Nerin Equipment Co., Ltd, Nanchang, 341000, China

    Zherui Qiu

Authors
  1. Zihang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yongfang Deng
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jincheng Zeng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Liang Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yutao Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Zherui Qiu
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Zihang Li: conceptualization, methodology, validation, formal analysis, investigation, writing—original draft, writing—revive and editing. Yongfang Deng: writing—revive and editing, resources, founding acquisition. Jincheng Zeng: conceptualization, methodology. Liang Hu: investigation. Yutao Zhou: investigation. Zherui Qiu: investigation. All authors agree to participate in the completion of the manuscript and the publication of the manuscript.

Corresponding author

Correspondence to Yongfang Deng.

Ethics declarations

Competing interests

The authors declare no competing interests.

Ethical approval

The submitted work is original and has not been published elsewhere. The manuscript was not submitted to more than one journal for simultaneous consideration.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, Z., Deng, Y., Zeng, J. et al. Achievement of defect-free and high-properties multilayer copper foils flexible connection by friction stir welding. Weld World (2023). https://doi.org/10.1007/s40194-023-01665-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40194-023-01665-6

Keywords

Search

Navigation