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<p>This study focused on the interfacial characterization and cracking phenomenon in dissimilar friction stir welded (FSWed) T-joints between aluminum alloy AA6061 and brass CuZn36 under the various welding speeds from 75 to 200&#xa0;mm/min. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD) were employed to characterize interface and intermetallic phases. Furthermore, the evolution of microstructure and microhardness was also investigated to clarify interfacial characterization. The results revealed that the welding interface was sensitive significantly to welding speed. A wider bonding region and stronger diffusion between Al, Cu, and Zn were achieved along the interface at low welding speed, resulting in the formation of Al<sub>2</sub>Cu, Cu<sub>4</sub>Zn, and CuZn<sub>5</sub> phases. However, excessive diffusion and thick intermetallic compounds (IMC) layer led to interfacial embrittlement and crack initiation approximately 74–240&#xa0;μm away from the interface toward aluminum side. In contrast, higher welding speeds reduced mixing and diffusion, producing poor metallurgical bonding. The hardness distribution along the stringer showed a maximum hardness of about 630 HV near the interface, resulting in the presence of a brittle diffusion and IMC layers. Overall, the results highlight the challenge of obtaining a defect-free T-joint between AA6061 and brass CuZn36, where controlling welding speed is critical to balancing interfacial bonding and crack prevention.</p>

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Interfacial characterization and cracking phenomenon in dissimilar friction stir welded T-joints between AA6061 and CuZn36

  • 期刊论文

  • 发表日期：

    2026年2月20日

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  • Hao Dinh Duong,
  • Quan Minh Nguyen,
  • Thuyen Van Phi,
  • Nam Hoai Quach,
  • Tra Hung Tran

摘要

This study focused on the interfacial characterization and cracking phenomenon in dissimilar friction stir welded (FSWed) T-joints between aluminum alloy AA6061 and brass CuZn36 under the various welding speeds from 75 to 200 mm/min. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD) were employed to characterize interface and intermetallic phases. Furthermore, the evolution of microstructure and microhardness was also investigated to clarify interfacial characterization. The results revealed that the welding interface was sensitive significantly to welding speed. A wider bonding region and stronger diffusion between Al, Cu, and Zn were achieved along the interface at low welding speed, resulting in the formation of Al2Cu, Cu4Zn, and CuZn5 phases. However, excessive diffusion and thick intermetallic compounds (IMC) layer led to interfacial embrittlement and crack initiation approximately 74–240 μm away from the interface toward aluminum side. In contrast, higher welding speeds reduced mixing and diffusion, producing poor metallurgical bonding. The hardness distribution along the stringer showed a maximum hardness of about 630 HV near the interface, resulting in the presence of a brittle diffusion and IMC layers. Overall, the results highlight the challenge of obtaining a defect-free T-joint between AA6061 and brass CuZn36, where controlling welding speed is critical to balancing interfacial bonding and crack prevention.