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<p>The micro-friction stir welding (μFSW) of Al/Cu composite ultra-thin sheets is challenging. It must not only overcome defects such as incomplete metallurgical bonding at the weld interface and weak bonding, which are caused by the rapid heat dissipation characteristic of thin plates, but also achieve lamellar metallurgical bonding to ensure structural integrity. This study investigates µFSW of a 1 mm explosion-bonded 1060 Al (0.7 mm)/T2 Cu (0.3 mm) composite ultra-thin sheet in a 'Cu-up and Al-down' configuration using a concave shoulder tool with 8 mm diameter at 9000 rpm rotation speed and 40 mm/min welding speed. The research examines the macroscopic plastic flow of metals, analyzes grain size, grain boundary angles, recrystallization distribution in different joint regions, and evaluates the microhardness and tensile strength of the joints. Results indicate that Cu side of the joint remains relatively intact, with a well-formed connection between the composite sheets. Under shoulder friction and upward forces, Al migrates upward, causing non-uniform thickness reduction in Cu. The microstructure of the Al side and Cu side has undergone varying degrees of refinement, with grain sizes of only 3.83&#xa0;μm and 2.72&#xa0;μm, respectively. Al side exhibits softening in microhardness, whereas the nugget zone near the advancing side achieves a microhardness of 82.61 HV, representing 131.7% of the base material's (BM) average hardness. Cu side experiences reduced hardness on RS due to plastic metal flow. The joint's average tensile strength is 156.8&#xa0;MPa, approximately 79.6% of the tensile strength of the original BM (197.1 MPa). Fractures primarily occur along the thinning region of Cu side on retreating side (RS) and exhibit a mixed mode of ductile and brittle failure.</p>

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Study on Microstructure and Properties of Friction Stir-Welded Joints of Al/Cu Composite Ultra-Thin Sheet Based on Optimized Parameters

  • 期刊论文

  • 发表日期：

    2025年11月1日

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  • Changqing Zhang,
  • Dong Wang,
  • Yu Ni,
  • Zhongke Zhang,
  • Defu Li,
  • Pengsheng Zhang

摘要

The micro-friction stir welding (μFSW) of Al/Cu composite ultra-thin sheets is challenging. It must not only overcome defects such as incomplete metallurgical bonding at the weld interface and weak bonding, which are caused by the rapid heat dissipation characteristic of thin plates, but also achieve lamellar metallurgical bonding to ensure structural integrity. This study investigates µFSW of a 1 mm explosion-bonded 1060 Al (0.7 mm)/T2 Cu (0.3 mm) composite ultra-thin sheet in a 'Cu-up and Al-down' configuration using a concave shoulder tool with 8 mm diameter at 9000 rpm rotation speed and 40 mm/min welding speed. The research examines the macroscopic plastic flow of metals, analyzes grain size, grain boundary angles, recrystallization distribution in different joint regions, and evaluates the microhardness and tensile strength of the joints. Results indicate that Cu side of the joint remains relatively intact, with a well-formed connection between the composite sheets. Under shoulder friction and upward forces, Al migrates upward, causing non-uniform thickness reduction in Cu. The microstructure of the Al side and Cu side has undergone varying degrees of refinement, with grain sizes of only 3.83 μm and 2.72 μm, respectively. Al side exhibits softening in microhardness, whereas the nugget zone near the advancing side achieves a microhardness of 82.61 HV, representing 131.7% of the base material's (BM) average hardness. Cu side experiences reduced hardness on RS due to plastic metal flow. The joint's average tensile strength is 156.8 MPa, approximately 79.6% of the tensile strength of the original BM (197.1 MPa). Fractures primarily occur along the thinning region of Cu side on retreating side (RS) and exhibit a mixed mode of ductile and brittle failure.