Cited by 146Advanced Welding Techniques AnalysisWelding Techniques and Residual StressesMetallurgy and Material Science

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Microstructure evolution and mechanical properties of friction stir spot welded dissimilar aluminum-copper joint

Zhou, L., Li, G.H., Zhang, R.X., Zhou, W.L., He, W.X., Huang, Y.X., Song, X.G.·2019·Journal of Alloys and Compounds

DOI 10.1016/j.jallcom.2018.10.045

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Abstract

Abstract Dissimilar lap joints of 1060 aluminum and T2 copper were obtained by friction stir spot welding (FSSW) at various rotational speeds. The measured process variables during welding revealed that an increasing rotational speed leads to a higher peak temperature but a lower torque and plunging force due to the greater softening degree of material. A continuous CuAl2-CuAl-Al4Cu9 laminated layer developed at the Al-Cu interface under the highest rotational speed, while the interface was characterized by the interruptedly distributed CuAl2 layer under lower rotational speeds. Intermetallic compound (IMC) formation sequence for CuAl2, CuAl and Al4Cu9 was predicted according to thermodynamic principles, which is consistent with the interfacial microstructure evolution identified by the transmission electron microscope (TEM). Besides the metallurgical bonding through the IMC layer at the Al-Cu interface, joints have a Cu hook extruded upward by the pin tool from the lower Cu sheet into the upper Al sheet, which provided additional mechanical interlocking between the sheets. Tensile properties of the joints were closely related to the thickness of the IMC layer and geometric features of the hook, higher tensile properties were found in joints owning a continuous interfacial IMC layer with a proper thickness as well as a high penetration depth of the hook into the upper Al sheet.

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Authors: Zhou, L., Li, G. H., Zhang, R. X., Zhou, W. L., He, W. X., Huang, Y. X., & Song, X. G.
Affiliations: Harbin Institute of Technology (CN)
Corresponding author: Zhou, L.
Huang, Y.X.
ORCID: Zhou, L.
He, W.X.
Huang, Y.X.
Song, X.G.
Venue: Journal of Alloys and Compounds
Publisher: Elsevier BV
Published: 2019-02
Volume: 775
Pages: 372-382
ISSN: 0925-8388 (ISSN-L)
DOI: 10.1016/j.jallcom.2018.10.045
OpenAlex: W2897614595
Cited by: 144
References: 36
Citations by year: 2026: 11 · 2025: 17 · 2024: 20 · 2023: 22 · 2022: 24 · 2021: 17 · 2020: 19 · 2019: 14
FWCI: 7.99
Type: journal article
Language: en
Open access: closed
Licence: www.elsevier.com/tdm/userlicense/1.0/ (tdm)
Locations: Journal of Alloys and Compounds (publishedVersion)
Funders: National Natural Science Foundation of China (51205084)
Natural Science Foundation of Shandong Province (ZR2016EEM43)
Topics: Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
Physical Sciences › Materials Science › Metals and Alloys › Metallurgy and Material Science
Keywords: friction stir spot welding, dissimilar metal joining, aluminum-copper joints, 1060 aluminum, T2 copper, rotational speed, intermetallic compound formation, CuAl2, CuAl, Al4Cu9, interfacial microstructure, metallurgical bonding, mechanical interlocking, tensile properties, peak temperature

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Microstructure evolution and mechanical properties of friction stir spot welded dissimilar aluminum-copper joint

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