Abstract
Medium-thick Al and Cu plates are commonly used in the power industry. However, it is difficult to achieve high-quality medium-thick Al/Cu dissimilar joints due to the formation of intermetallic compounds (IMCs) layer, which are typical Al2Cu, AlCu and Al4Cu9 phases. Although friction stir welding (FSW) is a suitable welding technique for joining dissimilar metals, the higher heat generation from a large tool shoulder when FSW of medium-thick plates significantly reduces the joint properties. Therefore, a novel double-side friction stir Z shape butt-lap welding (DS-FSZW) is proposed to join medium-thick Al/Cu dissimilar plates. The results indicated that the DS-FSZW reduces the thickness of the IMCs layer compared with conventional double-side FSW (DS-FSW). The maximum tensile strength and elongation of the DS-FSZW joint are 174.17 MPa and 7.32 %, respectively. While the maximum tensile strength and elongation of DS-FSW are 140.98 MPa and 6.2 %, respectively. It indicates the novel DS-FSZW can effectively increase the mechanical properties of the medium-thick Al/Cu dissimilar joints compared to DS-FSW.
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