4 mm

9 mm

1 mm 1 mm 2 mm
 1600

1400

1200 SS_Bottom
SS_Top
Temperature (Degree C)

Al_Top
1000
Al_Bottom
Copper_Top
800 Copper_Bottom

600

400

200

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Time(Sec)
 Targeted materials Process inputs Process performance
(thickness)
Tool design Process parameters
• 1 mm-thick joints of • Scrolled tool promoted the formation of a
oxygen-free copper tongue-shaped mixing region almost
with high phosphorous exclusively composed of CuAl2 where, the
content (Cu-DHP, R conical tool gave rise to the formation of an
240) and 5083-H111 aluminium, copper, CuAl2 and Cu9Al4 mixture,
aluminium alloy (AA
5083-H111) with higher heterogeneity and lower
intermetallic content.
• Copper plate was
placed at the • An irregularly distributed intermetallic-rich
advancing side of the material, with strong non-metallic
tool characteristics, was observed on surface of
the welds carried out with the conical tool,
where a regular surface with no significant
amount of intermetallic material was depicted
in the welds produced with the scrolled tool.

• Large formation of intermetallic material,

specifically CuAl2, on the surface of the
conical weld results from material mixing in
the under shoulder volume, which contains
large amount of aluminium that is constrained
inside the conical cavity of the tool.

• Since no accumulation of material is

promoted under the scrolled shoulder, there is
no intermetallic deposition at the weld surface.

Galvao et. al. (2012

 Targeted materials Process inputs Process performance
(thickness)
Tool design Process parameters
• 1.0 mm thick 6061-T6 • Tool material: H13 steel. • Constant • Cu particles consisting of pure Cu and Al/Cu IMCs
aluminum alloy and rotational speed: were dispersed in the Al matrix to form composite-like
T2 pure copper ultra- • Shoulder diameter: 6.5 mm- 3000 rpm structure. The nugget zone consisted mainly of several
thin sheets were diameter concave shoulder IMCs, including Al2Cu and Al4Cu9, based on XRD
friction stir butt- with triple helix. • Traverse speeds analysis. A few lamellar structure containing excessive
welded. of 50, 80, 120, and IMCs were observed on the Cu side near Al/Cu
• Pin type: Unthreaded conical 150 mm/min. interface.
• The Al plate was pin.
settled at advancing • The Al/Cu joints achieved metallurgical bonding. The
side. • Tip diameter: 2.5 mm. Al2Cu, AlCu and Al4Cu9 layers were formed at the Al/
Cu interface due to atomic interdiffusion of Al and Cu.
• Tool pin was offset to • Root diameter 2.0 mm. A higher traverse speed could reduce peak
the Al side with a temperature and shorten holding time of elevated
distance of 0.8 mm • Length: 0.82 mm. temperature, which leads to the decrease of IMCs layer
from the welds butt thickness.
line.
• The hardness distribution of the nugget zone was
inhomogeneous, where the maximum hardness
reached 138.7 HV. Furthermore, the hardness of
lamellar structure was significantly higher than that of
Al and Cu base metals. The formation of IMCs in the
nugget zone and lamellar structure was responsible to
the hardness increase.

• The maximum tensile strength of the Al/Cu joint

reached up to 236.2 MPa, whose joint efficiency was
82.9 % of the Cu base metal. In this case, the FSW Al/
Cu joints failed in the HAZ of the aluminum side, and
the fracture surface exhibited ductile fracture
Mao et. Al. (2020)
 Targeted materials Process inputs Process performance
(thickness)
Tool design Process parameters
• Commercial grade • Tool material: H13 steel. • Constant rotational • The lap welds were having better tensile
aluminum alloys speed: properties than the butt welds in both
of thickness 0.44 • Tool geometry: As below image. 1. For butt weld transverse and longitudinal tensile tests.
mm configuration 1650 rpm.
2. For lap weld • Nugget between the sheets revealed thinning of
configuration 1700 rpm. material as the reason for failure.

• Tool traverse speed: 25 • No significant difference between lap and butt

mm/min. joint hardness trend could be observed

• It was observed that the more the material is

available for stirring, the stronger is the joint.
Butt config Lap config

• Tool machining: Micro-turning on

DT-110 (high precision
multipurpose machine tool).

Mao et. Al. (2020)

 Targeted materials Process inputs Process performance
(thickness)
Process set up Process parameters
Sheets of aluminum • The welding time was • Using the thermo- compensating process tape,
alloy 5052 (AA5052) incrementally increased aluminum alloy and commercial pure copper
and T2 grade to 100, 200, 300, 400, could be joined by the resistance spot welding
commercial 500 and 600 ms. technique.
pure copper (CP-Cu)
with thicknesses of 1 • The welding current was • A massive region of the α-Al solid solution and a
mm were used. in the range from 8 to 16 thin transition layer that consisted of the α/θ
kA with an interval of 2 eutectic phase and θ-CuAl2 was formed in the
kA. weld nugget made by normal heat input.

• Electrode force was fixed • When the heat input was high, the
at 4 kN. microstructure converted into a massive θ-
CuAl2 region combined with an η2-CuAl layer at
the Cu side and α/θ eutectic phase at the Al side.

• The tensile shear properties of the joints were

affected by both the weld physical properties
• All the samples were welded using and metallurgical factors.
a 220 KW medium frequency
direct current resistance spot • When formed under normal heat input, the
welding machine. shear strength of the joints was higher than
that formed under high heat input.