Mechanical strength optimisation of additively manufactured parts has been attracting attention in recent years.

Copper cladding on steel, combines the corrosion resistance of copper with the high tensile strength of steel and is being employed in several applications.

This work successfully clads a 3 mm thick copper sheet on a 6 mm thick mild steel substrate using the friction stir welding (FSW) method. The procedure differs from lap welding in such that multiple FSW passes are required to completely cover the substrate's surface using an optimum tool offset to cover the broader width of the clad layer.

Optical microscopy, SEM-EDS, and microhardness testing were used to perform metallurgical analysis on the transverse cross-section of the cladded samples.

At the interface of the two materials, surface jetting-type characteristics similar to explosive welding were observed. Even though there was a plastic flow of material, the substrate material was unable to reach the clad layer's top surface.

Uniaxial tensile tests reveal the strength of clad composite in between base copper and base steel.

Fractography analysis shows no delamination or peeling between cladding and substrate material. For the steel substrate, higher hardness values were observed in the stir zone for single-pass clad due to grain refinement.

This article is shared by Mithlesh Kumar Mahto, Adarsh Kumar, Meghanshu Vashista, Mohd. Zaheer Khan Yusufzai