The T2 Cu with a thickness of 0.2 mm and 6063 Al alloy with a thickness of 0.4 mm were joined via nanosecond pulsed laser welding in an inner spiral scanning mode. The lap configuration was Cu (upper)/Al (under). The influence of spiral scan distance (spiral distance for short) on the weld formation, microstructure and mechanical property was investigated. The results showed that circular holes and arc-shaped cracks formed on the weld surface at the spiral distance of 0.02 mm, and these defects disappeared at higher spiral distances. The tendency of porosity increased initially and decreased afterwards as the spiral distance increased. The interfacial morphology exhibited a wave-shaped structure at the spiral distance of 0.02 mm, and a continuous lump θ-CuAl2 phase was produced at the interface. When the spiral distance was larger than 0.02 mm, the wave-shaped structure disappeared and V-shaped areas were generated due to the invasion of Al element into Cu base metal. α-Al and θ-CuAl2 phases were possibly produced in these areas. The Cu-rich areas generated on the sidewall of the weld could cause the formation of θ-CuAl2. According to the tensile-shear load results, the maximum shear force reached 107.7 N at the spiral distance of 0.04 mm. The satisfactory weld formation and larger effective bounding area contributed to the superior bonding strength. Three fracture modes (button pulling out failure, weld shear failure and interface failure) were observed in this study.
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