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<p>This study investigates the critical interaction between welding direction and tool offset on the properties of dissimilar friction stir welded (FSW) joints between pure copper (C1100) and aluminum 1050 (AA1050). Two welding configurations, designated FSW1 and FSW2, were employed with identical linear tool offset variations (3.3–4.0&#xa0;mm) but opposite welding directions to fabricate butt joints from 5.0&#xa0;mm thick plates. The research comprehensively examines material flow patterns, interface morphology evolution, intermetallic compounds (IMCs) formation, mechanical properties, and fracture mechanisms. Experimental results revealed significant differences in joint characteristics: FSW1 exhibited superior material flow stability, thinner IMC layers (0.3–0.5&#xa0;μm), and higher tensile strength (reaching 102&#xa0;MPa) compared to FSW2, which showed continuous thick IMC formation and lower strength (88&#xa0;MPa). Fracture analysis demonstrated distinct failure modes, with FSW1 displaying variable fracture locations along the weld path while FSW2 consistently failed at the Cu/Al interface. Finite element analysis quantified stress concentration factors (SCFs) at interface discontinuities, revealing higher SCFs in FSW2 specimens correlating with reduced joint strength. The findings demonstrate that the synergistic effect of welding direction and tool offset critically influences dissimilar joint quality, providing essential insights for optimizing FSW parameters in Cu/Al joining applications. This research contributes to the fundamental understanding of process-structure-property relationships in dissimilar metal welding, particularly relevant for electrical and automotive industry applications.</p>

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Welding direction and tool offset interaction in dissimilar friction stir welding of pure copper and aluminum: interface evolution, mechanical properties, and fracture mechanisms

  • 期刊论文

  • 发表日期：

    2025年12月8日

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  • Quach Hoai Nam,
  • Duong Dinh Hao,
  • Tran Hung Tra

摘要

This study investigates the critical interaction between welding direction and tool offset on the properties of dissimilar friction stir welded (FSW) joints between pure copper (C1100) and aluminum 1050 (AA1050). Two welding configurations, designated FSW1 and FSW2, were employed with identical linear tool offset variations (3.3–4.0 mm) but opposite welding directions to fabricate butt joints from 5.0 mm thick plates. The research comprehensively examines material flow patterns, interface morphology evolution, intermetallic compounds (IMCs) formation, mechanical properties, and fracture mechanisms. Experimental results revealed significant differences in joint characteristics: FSW1 exhibited superior material flow stability, thinner IMC layers (0.3–0.5 μm), and higher tensile strength (reaching 102 MPa) compared to FSW2, which showed continuous thick IMC formation and lower strength (88 MPa). Fracture analysis demonstrated distinct failure modes, with FSW1 displaying variable fracture locations along the weld path while FSW2 consistently failed at the Cu/Al interface. Finite element analysis quantified stress concentration factors (SCFs) at interface discontinuities, revealing higher SCFs in FSW2 specimens correlating with reduced joint strength. The findings demonstrate that the synergistic effect of welding direction and tool offset critically influences dissimilar joint quality, providing essential insights for optimizing FSW parameters in Cu/Al joining applications. This research contributes to the fundamental understanding of process-structure-property relationships in dissimilar metal welding, particularly relevant for electrical and automotive industry applications.