Mechanical Characterization of Copper-Copper Wires Joined by Friction Welding Using Instrumented Indentation Technique

Friction welding samples of both the fire-refined high-conductivity (FRHC) and electrolytically tough pitch (ETP) copper alloy wires have been mechanically characterized by instrumented indentation technique and tensile test. Hardness profiles in the perpendicular direction to the weld interface, in both the central and peripheral zones, of the as-welded FRHC-FRHC and ETP-ETP samples have been investigated at nano-/micrometric scale. The microstructures of welds have been observed using both the optical microscopy and scanning electronic microscopy. The results show the typical friction welding zones: the interface zone, the thermo-mechanically affected zone (TMAZ), and the transition zone between the TMAZ and the base metal zone (BMZ) that present a microstructure and hardness close to the base metal. No presence of a heat-affected zone is observed. Although both welds show the same tendency in hardness distribution, FHRC-FHRC weld presents a TMAZ narrower than ETP-ETP one, which produces a stronger drop in hardness with increasing of the distance from welding central line, and a higher difference in hardness between the central and peripheral zones. The tensile tests of ETP-ETP welds showed that all samples broke by the BMZ that is far away from the interface of the welded joint, while the most of the FRHC-FRHC welds are broken at the TMAZ region at low strengths. These appreciable differences in mechanical properties for the FHRC-FHRC welds are probably generated by a stronger variation in their microstructural properties. Therefore, it may justify the welding failures in the FHRC-FHRC weld at the typical tensile stress for an industrial cold-drawn process of wires.