Investigation of interdiffusion and intermetallic compounds in Al–Cu joint produced by continuous drive friction welding
Open accessAbstract
In this paper, the joints between Al and Cu bars were fabricated by continuous drive friction welding. The microstructures and the compositions of the composites were analyzed by SEM, EDS and XRD. The surface temperature was observed using an infrared thermographic camera. The interface temperatures were suggested in the range of 648~723 K at different welding parameters. The interdiffusion between Al and Cu atoms is extraordinarily rapid, as the interdiffusion coefficients could reach 7.8 × 10−12 m2/s. Intermetallic phases Al2Cu and Al4Cu9 were identified in all samples in view of the XRD and EDS analyses. The effective Gibbs free energy change of formation model was proposed to predict the Al–Cu compound formation at solid-state interface, and the calculation combined with kinetic factors showed that Al2Cu (Al side) and Al4Cu9 (Cu side) appeared first.
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Fusion welding Al and Cu is challenging due to the formation of intermetallic compounds at the interface, necessitating the use of solid-state welding techniques.
“However, it has been reported that fusion welding Al and Cu is challenging due to the formation of intermetallic compounds at the interface, necessitating the use of solid-state welding techniques [29,30].”
From Multi-layer solid-state ultrasonic additive manufacturing of aluminum/copper: local properties and texture (2024) · cites this paper as [30]
The Introduction (page unavailable) says Al and Cu form brittle intermetallics at their interface, which affect manufacturability. The paper studies solid-state friction welding, but does not specifically say fusion welding is challenging or that solid-state techniques are necessary; its Conclusions report intermetallics even in the friction-welded joints. (LLM, conf=0.86)
Experimental — accuracy not yet measuredThe formation of intermetallic compounds has been considered in some studies as a reason behind the elevated hardness near the interface.
“In addition to work hardening, the formation of intermetallic compounds has also been considered in some studies [16,29,30,42] as a reason behind the elevated hardness near the interface.”
From Multi-layer solid-state ultrasonic additive manufacturing of aluminum/copper: local properties and texture (2024) · cites this paper as [30]
Section 3.2 (page unavailable) identifies intermetallic compound layers at the Al–Cu interface, and the Introduction says such phases affect joint properties. The paper does not report elevated hardness near the interface or attribute it to those compounds (searched: hardness, microhardness, work hardening). (LLM, conf=0.83)
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Research works printed but not linked: 3
- Y. Funamizu, K. Watanabe, Interdiffusion in Al-Cu System, Trans. Jpn. Inst. Met. 12 (3) (1971) 147-152.
- G. Neumann, C. Tuijn, Self-Diffusion and Impurity Diffusion in Pure Metals: Handbook of Experimental Data, Elsevier, Amsterdam, 2009, pp. 45-54.
- L. Yang, B.X. Mi, L. Lin, H.J. Huang, X.P. Lin, X.G. Yuan, Formation sequence of interface intermetallic phases of cold rolling Cu/Al clad metal sheet in annealing process. China Materials Conference: 23 W material surface and interface, 2012, pp. 1-6.
Cited by
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Behvar, A., Shakil, S. I., Pirgazi, H., Norfolk, M., & Haghshenas, M. (2024) · The International Journal of Advanced Manufacturing Technology · doi:10.1007/s00170-024-13490-2 · Cited by 18 · see citing works
Sauter, L., Weihe, S., & Werz, M. (2026) · Results in Engineering · doi:10.1016/j.rineng.2026.111762 · Cited by 1 · see citing works
Sun, Y., Ni, C., Xiao, H., Liu, Z., & Liu, D. (2025) · Materials Testing · doi:10.1515/mt-2024-0550
- Authors
- Wei, Y., Li, J., Xiong, J., & Zhang, F.
- Affiliations
- Northwestern Polytechnical University (CN)
- Corresponding author
- Li, Jinglong
- Venue
- Engineering Science and Technology, an International Journal
- Publisher
- Elsevier BV
- Published
- 2016-03
- Volume
- 19
- Issue
- 1
- Pages
- 90-95
- ISSN
- 2215-0986 (ISSN-L)
- OpenAlex
- W1127876578
- Cited by
- 82
- References
- 0
- Citations by year
- 2026: 7 · 2025: 14 · 2024: 8 · 2023: 9 · 2022: 10 · 2021: 10 · 2020: 3 · 2019: 5 · 2018: 8 · 2017: 5 · 2016: 3
- FWCI
- 5.24
- Type
- journal article
- Language
- en
- Open access
- gold
- doi.org
- Licence
- Locations
- Engineering Science and Technology an International Journal (publishedVersion, cc-by-nc-nd)
- DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion, cc-by-sa)
- Funders
- State Key Laboratory of Solidification Processing in NWPU (43-QP-2009, 31-TP-2009)
- 111 Project (B08040)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
- Physical Sciences › Engineering › Mechanical Engineering › Intermetallics and Advanced Alloy Properties
- Physical Sciences › Materials Science › Materials Chemistry › Metallurgy and Material Science
- Keywords
- continuous drive friction welding, interdiffusion, intermetallic compounds, Al2Cu, Al4Cu9, interdiffusion coefficient, interface temperature, Gibbs energy of formation, solid-state interfaces, welding parameters, aluminum-copper dissimilar joining
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