Damaged surface morphology of AA6063/Cu30Zn parts joined with a new technology by friction-mechanical locking method

Mechanical locking method is a novel and environmentally friendly technique used to join dissimilar materials with a low heat input. In this method, no connection at the atomic level is expected between the types of materials that are combined, called molds and reshaped parts. On the other hand, different types of materials such as copper, steel, aluminum and non-metallic ceramics can be combined with each other, provided that the reshaped part has melting properties. In a previous study, the aluminium alloy AA6063 and Cu30Zn brass material pair, which have different physical, chemical, thermal, and mechanical properties, was joined by mechanical locking method. The effects of different rpm values (900, 1120, and 1400 rpm) used in joining processes on the joint quality were investigated. This study investigated the damaged surface morphology of the samples whose mechanical tests were completed. For this purpose, detailed SEM and EDX examinations of damaged surfaces were completed. The damage processes of the metal joined by heat and pressure and significant changes in its microstructure were thoroughly assessed. As a result, it was determined that insufficient heat during the joining process significantly negatively affected the damage processes. When sufficient heat values were reached, the load-bearing joint metal had a more regular microstructure and a linear joint area. This was the main reason for the increase in mechanical properties.