Abstract
Morphological, metallographic and structural analyses of aluminium–copperdissimilar welds produced under different friction stir welding conditionswere conducted in order to analyse the mechanisms of intermetallic phasesformation, its relation with welding conditions and its consequences in theweld structure and morphology. Under lower heat input conditions, only a thinintermetallic layer distributed along the aluminium/copper interface was depictedinside the nugget. Increasing the heat input promoted material mixing andformation of increasing amounts of intermetallic rich structures. The intermetallicphase content and the homogeneity of the mixed area increased with increasingheat input, evolving from structures containing Al, Cu, CuAl2 andCu9Al4 to structures predominantly composed of Cu9Al4and Cu(Al). In order to explain these results, the mechanisms ofintermetallic phases formation are discussed, taking into account the processparameters and material flow mechanisms in friction stir welding. Importantrelations between intermetallic formation and weld surface morphology werealso found.
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