Abstract
In this work, plates of dissimilar Al/Cu alloys were butt jointed by friction stir welding (FSW) with and without ultrasonic vibration. It was found that the assistance of ultrasonic vibration produced slight variations of both mechanical interlocking and material intermixing of dissimilar material, as well as fracture location during tensile tests, but it particularly reduced the thickness of intermetallic compounds (IMCs) layer in the middle part of the Al/Cu joint. Therefore, by homogenizing the IMCs distribution along the bonding interface within a thickness of 1.0 µm, the tensile strength of the Al/Cu FSW joint was improved from 195.5 to 215.0 MPa with the assistance of ultrasonic vibration.
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