Effect of pin offset on interface evolution and fracture behavior of aluminum/copper dissimilar friction stir welded

Abstract

In this study, triangular prismatic threaded structural pins at different offsets were used to study the forming and performance of Al/Cu dissimilar joints. In the experiments, the Al alloy was placed on the advancing side, and the stirring pin was offset 0.5 mm, 0.8 mm, 1.0 mm, and 1.2 mm towards the Al side, respectively. The results show that sound joints can be obtained under each offset. The number and size of Cu particles in the stirred zone of the joint with a pin offset of 0.5 mm was large. The Cu particles in the stirred zone gradually refine as the stirring pin is offset towards the Al side. According to the EDS analysis, the stirring zone and interfacial intermetallic compounds (IMCs) mainly consist of Al2Cu and Al4Cu9, and a lamellar structure with IMC layers was observed on the Cu side near the Al/Cu interface. The size and number of Cu particles as well as the thickness of the IMCs layer had a significant effect on the tensile strength of the joints, with a maximum tensile strength of 203.4 MPa (equivalent to 71.3% of the Cu base metal) obtained at a pin offset of 1 mm, which was fractured in the heat-affected zone on the Al side, and the fracture surfaces demonstrated ductile fracture.