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Cited by 45Advanced Welding Techniques AnalysisAluminum Alloy Microstructure PropertiesElectronic Packaging and Soldering Technologies

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Unveiling non-equilibrium metallurgical phases in dissimilar Al-Cu joints processed by vaporizing foil actuator welding

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Wang, Kaifeng, Shang, Shun-Li, Wang, Yuxiang, Vivek, Anupam, Daehn, Glenn, Liu, Zi-Kui, Li, Jingjing·2020·Materials & Design
DOI 10.1016/j.matdes.2019.108306
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Abstract

An integrated experimental and computational approach has been adopted to investigate the formation mechanism of intermetallic compounds (IMCs) in dissimilar Al-Cu joints processed by vaporizing foil actuator welding (VFAW). Aiming to understand the formation of IMCs and their transition, the present work employed first-principles calculations of thermodynamic properties as a function of temperature and pressure together with diffusivities of Al and Cu from the literature. Agreeing with experimental observations, the predicted IMC formation sequence in the low-energy welding region is as follows. θ-Al2Cu forms first due to the fast diffusivity of Cu in the Al-matrix. θ-Al2Cu then transforms to η2-AlCu because of the fast diffusivities of Al/Cu in θ-Al2Cu. In the high-energy welding region, the stable γ1-Al4Cu9 and the metastable θ’’-Al3Cu are also formed in addition to the aforementioned θ-Al2Cu and η2-AlCu. η2-AlCu and considerable γ1-Al4Cu9 are the major phases in the high-energy welding region. The present approach, combining experiments and calculations, is proven to be a practical way to understand non-equilibrium metallurgical processes, as demonstrated through the study of VFAW Al-Cu joints.

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  • Ultrasonic welding can realize a strong connection between Al wire harness and coated terminal.

    “Ultrasonic welding can realize strong connection between Al wire harness and coated terminal, which is widely used in production of automotive wire harness, electronic industry, communication equipment and photovoltaic industry10.”

    From Investigation of joint formation in aluminum wire and nickel-coated copper terminals using ultrasonic welding (2025) · cites this paper as [10]

    The Introduction (page unavailable) says ultrasonic welding has been employed for Al–Cu joining, supporting the general point that it can join these materials. It does not address the strength of an Al wire-harness-to-coated-terminal connection or the claimed use across the listed industries. The Methods instead describe vaporizing foil actuator welding of Al and Cu sheets. (LLM, conf=0.84)

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Metadata

Authors
Wang, K., Shang, S.-L., Wang, Y., Vivek, A., Daehn, G., Liu, Z.-K., & Li, J.
Affiliations
  • Pennsylvania State University (US)
  • The Ohio State University (US)
Corresponding author
Li, Jingjing
ORCID
Venue
Materials & Design
Publisher
Elsevier BV
Published
2020-01
Volume
186
Pages
108306
ISSN
0264-1275 (ISSN-L)
DOI
10.1016/j.matdes.2019.108306
OpenAlex
W2983338129
Cited by
45
References
0
Citations by year
2026: 6 · 2025: 7 · 2024: 8 · 2023: 4 · 2022: 3 · 2021: 9 · 2020: 8
FWCI
2.81
Type
journal article
Language
en
Open access
Licence
Locations
  • Materials & Design (publishedVersion, cc-by-nc-nd)
  • DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion, cc-by-sa)
  • OSTI OAI (U.S. Department of Energy Office of Scientific and Technical Information) (submittedVersion)
Funders
  • National Science Foundation
  • U.S. Department of Energy
Topics
  • Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
  • Physical Sciences › Materials Science › Metals and Alloys › Aluminum Alloy Microstructure Properties
  • Physical Sciences › Engineering › Electrical and Electronic Engineering › Electronic Packaging and Soldering Technologies
Keywords
dissimilar metal joining, aluminum-copper joints, intermetallic compound formation, interfacial reaction, atomic diffusivity

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