Effect of zinc interlayer on ultrasonic spot welded aluminum-to-copper joints

Dissimilar aluminum (Al) and copper (Cu) metals were joined together using ultrasonic spot welding (USW), a solid state welding technology. The welds were made with and without a zinc (Zn) interlayer to study the microstructural and mechanical properties of weld joints to analyze the effect of the Z...

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Bibliographic Details
Published in:Materials science & engineering. A, Structural materials : properties, microstructure and processing Structural materials : properties, microstructure and processing, 2014-06, Vol.607, p.277-286
Main Authors: Balasundaram, R., Patel, V.K., Bhole, S.D., Chen, D.L.
Format: Article
Language:English
Subjects:
Aluminum
Aluminum alloy
ALUMINUM ALLOYS (50 TO 99 AL)
Aluminum base alloys
Applied sciences
Copper
Cross-disciplinary physics: materials science
rheology
Elasticity and anelasticity
Exact sciences and technology
INTERLAYERS
Intermetallic compound
Joining, thermal cutting: metallurgical aspects
JOINTS
Materials science
Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology
Metals. Metallurgy
Microstructure
MICROSTRUCTURES
Physics
Shear
SPOT WELDING
Treatment of materials and its effects on microstructure and properties
Ultrasonic spot welding
ULTRASONICS
Welded joints
WELDING
Zinc
Zinc interlayer
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Summary:Dissimilar aluminum (Al) and copper (Cu) metals were joined together using ultrasonic spot welding (USW), a solid state welding technology. The welds were made with and without a zinc (Zn) interlayer to study the microstructural and mechanical properties of weld joints to analyze the effect of the Zn interlayer. USWed Al-to-Cu joints did not produce any intermetallic compounds (IMCs), and only swirls and voids were observed. It was determined through energy dispersive X-ray spectroscopy and X-ray diffraction scans that welds with a Zn interlayer placed in-between the faying surfaces of the base metals formed a composite-like eutectic structure of Al and Al2Cu at the center and Al–Zn and CuZn5 at the edges of the welded joint. Al–Cu joints welded with a Zn interlayer in-between displayed lap shear tensile strengths 25–170% greater than those of the welds without any interlayer.
ISSN:0921-5093
1873-4936
DOI:10.1016/j.msea.2014.03.135