Friction Stir Welding Process of Aluminum/Copper Heterogeneous Metals

JIA Lulu; ZHAO Shujie; SUN Wukui; ZHOU Shaozhen; WU Mingxiao; JING Yuankun; YE Weicheng; GAO Song; SHI Lei

doi:10.3969/j.issn.1674-6457.2025.08.021

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (8) : 203-212. DOI: 10.3969/j.issn.1674-6457.2025.08.021

Advanced Manufacturing Technology and Equipment

Friction Stir Welding Process of Aluminum/Copper Heterogeneous Metals

JIA Lulu¹, ZHAO Shujie², SUN Wukui³, ZHOU Shaozhen², WU Mingxiao², JING Yuankun⁴, YE Weicheng⁴, GAO Song^4,*, SHI Lei⁵

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Abstract

The work aims to explore the effects of welding processes at different speeds on the microstructure and properties of aluminum/copper stir friction lap welded joints. In this study, friction stir lap welding of 2.5 mm thick 6061-T6 aluminum alloy and 2 mm thick T2 pure copper aluminum/copper dissimilar materials were mainly achieved by controlling the welding process parameters of the stirring head speed. Lap joints with beautiful surface forming, good interface bonding, excellent mechanical properties and corrosion resistance was successfully obtained. The surface forming, cross-sectional microstructure, fracture morphology, fracture mode, tensile properties and corrosion resistance of such joints were studied and analyzed. The experiment found that the fracture modes of the FSW lap joint obtained were mainly divided into two types: direct interface peeling and copper side “aluminum adhesion” interface fracture. Among them, the joint with copper side “aluminum adhesion” interface fracture mode had the best performance; And an extremely rare combination of “rock sugar” like patterns and tough dimples was observed in the microscopic image of the fracture surface of the “sticky aluminum” fracture; In the macroscopic joint cross section, the width of the weld nugget zone (WNZ) and the interface zone (IZ), as well as the height of the hook shaped structure, would gradually increase due to the increase of heat input; In the corrosion test, it was found that the area with the worst corrosion resistance of the joint was the heat affected zone on the aluminum side, followed by the weld nugget zone and the interface between aluminum and copper. The variation of stirring head speed could lead to changes in heat input, thereby affecting the bonding and various properties of aluminum/copper welded joints. In conclusion, in aluminum/copper stir friction lap welding, the speed of the stirring head has a significant impact on the surface formation of the weld, the microstructure of the cross-sectional area of the welded joint, the fracture mode and morphology, tensile shear properties, and corrosion properties.

Key words

friction stir welding / aluminum/copper overlap / welding seam formation / fracture morphology / tensile shear load / corrosion performance

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JIA Lulu, ZHAO Shujie, SUN Wukui, ZHOU Shaozhen, WU Mingxiao, JING Yuankun, YE Weicheng, GAO Song, SHI Lei. Friction Stir Welding Process of Aluminum/Copper Heterogeneous Metals[J]. Journal of Netshape Forming Engineering. 2025, 17(8): 203-212 https://doi.org/10.3969/j.issn.1674-6457.2025.08.021

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Funding

Science and Technology Planning Project of State Grid Henan Electric Power Company (52170220009Y); Shandong University Research Commission Project (QL2021317)