Factors influencing Al-Cu weld properties by intermetallic compound formation

Abstract

Dissimilar welding of aluminium (Al) and copper (Cu) has many applications in the electric power, electronic and piping industries. The weldments in these applications are highly valued for their corrosion resistance, heat and electricity conducting properties. The Al-Cu joints are lighter, cheaper and have conductivity equal to that of copper alloys. Much research has investigated dissimilar welding of Al-Cu by solid-state welding and fusion welding processes with the aim of optimising the properties and strength of such dissimilar joints. The main aim of the study is to critically review the factors influencing the properties of the Al-Cu joint. The study mainly discusses about the effects of intermetallic compounds (IMC) on the properties of Al-Cu joint and their effect while in service. The effects of joining aluminium alloy 1060 with pure copper by laser welding, friction stir welding and brazing have been reviewed and compared. The review shows that the various intermetallic compound formations in the joint have both beneficial and detrimental effects. The characteristics of these intermetallic compounds vary according to the location of the phase formed. Comparison of processes and parameters for welding of Al 1060 with pure Cu shows that the formation of the intermetallic compounds and their effects on the weld properties are mainly influenced by the welding speed, heat input, the thermal properties of the base metals and the filler metal as well as the dilution between the base metal and filler metal.

Influence of Pin Length and Electrochemical Platings on the Mechanical Strength and Macroscopic Defect Formation in Stationary Shoulder Friction Stir Welding of Aluminium to Copper

“…Therefore, various applications require the joining of dissimilar joints without deteriorating the electrical and mechanical properties at the interface. In solid state welding, the fabrication of dissimilar joints between aluminium and copper has been the subject of various investigations [1][2][3]. In order to ensure good electrical properties of the dissimilar joints, the objective of available welding technologies is to obtain a high bond strength combined with maximum contact area.…”

Fiber laser welding of AA 5754 in the double lap-joint configuration: process development, mechanical characterization, and monitoring

“…The relevance of aluminum alloys in industrial applications has grown in the last years due to the necessity of lightweight design of mechanical components. In particular, in the automotive sector electric vehicles are gaining importance [1], and aluminum alloys are the first choice as lightweight materials for many components like car bodies and batteries casings [2][3][4][5]. Concerning the assembly of aluminum alloy components, laser beam welding has become an established solution in the industry.…”

Influence of Tool Material, Tool Geometry, Process Parameters, Stacking Sequence, and Heat Sink on Producing Sound Al/Cu Lap Joints through Friction Stir Welding

“…Another interesting application of Al-Cu sheet is that it can be employed as a fire-resistant material [2]. Numerous conventional joining techniques such as brazing and laser welding are applied to join Al and Cu but it is challenging because of the difference in the physical and chemical properties of the metals and the tendency to form brittle intermetallic compounds (IMCs) during the formation of welded joints [3]. These IMCs can impair the mechanical and electrical properties of the joint [4].…”