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Abstract
The present study aims to enhance the mechanical performances of friction stir lap welded Al-Zn-Mg-Cu aluminum alloy joint by using a Cu foil interlayer at the faying surface. The results show that the diffusion of alloying element Zn of the Al-Zn-Mg-Cu aluminum alloy is promoted towards the Cu interlayer at faying surface during friction stir lap welding. Furthermore, Cu(Zn) solid solution rather than Cu-Zn intermetallic compounds is mainly produced after the diffusion of Zn atoms into Cu interlayer. Worthy of note is that the presence of Cu interlayer has an evidently positive effect on joint strength. Such a design to improve the bonding strength through adding metal foil interlayer provides a new technological approach for high-quality friction stir lap welding or even friction stir additive manufacturing.
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