Review
Chemistry, Physical
Sergey Kuryntsev
Summary: This paper analyzes articles published from 2016 to 2021 on the topic of welding of dissimilar alloys and finds that laser welding is widely used for metal pairs such as Al/Fe, Al/Ti, and Al/Cu. The paper examines the impact of laser welding techniques on the mechanical properties and thickness of intermetallic compounds.
Article
Engineering, Mechanical
Suman Chatterjee, Lanh N. Trinh, Dongkyoung Lee
Summary: Laser beam welding (LBW) has wide applications, and joining of different materials is challenging. However, the quality of the welded joints can be improved by varying the laser powers.
JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Soon-Jae Lee, Kwang-Deok Choi, Su-Jin Lee, Dong-Sik Shin, Jae-Pil Jung
Summary: In order to improve the reliability and safety of electrical components in automobiles, researchers have used copper and aluminum as electrodes and employed lasers for rapid welding. However, in the welding of dissimilar metals such as aluminum and copper, the presence of intermetallic compounds (IMCs) reduces the strength of the weld. By using a high-quality laser with a high beam quality, researchers were able to increase the absorption rate and study the impact of welding speed on fracture behavior.
Review
Optics
Bo Ma, Xiangdong Gao, Yijie Huang, Perry P. Gao, Yanxi Zhang
Summary: Dissimilar metal composite structures are widely used to meet the requirements of lightness, corrosion resistance, electrical conductivity, and thermal conductivity. The use of dissimilar aluminium (Al) and copper (Cu) for lithium battery welding is increasingly discussed due to global energy conservation and emission reduction policies. Laser welding is a unique technology for Al and Cu, but it faces challenges such as poor laser absorption, unstable welding process, and formation of brittler intermetallic compounds (IMCs). This paper discusses the challenges and analyzes the effect of process parameters and laser output modes on the weld joint, as well as the research progress on filler metals and process monitoring.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Luxin Chi, Chuan Liu, Shifa Liang
Summary: In this study, a dissimilar metal joint of 2024 aluminum alloy and pure copper was prepared using EMPW method, and the stress distribution in the joint was analyzed using the contour method. The results show a steep stress gradient with tensile stress and compressive stress occurring in different sides of the joint.
Article
Automation & Control Systems
Joonghyeon Shin, Minjung Kang
Summary: This study investigates the effects of lap configurations and process parameters on the tensile-shear load, T-peel load, and composition distribution when multi-layered joints of dissimilar materials are produced by laser welding. The results show that the lap configuration and welding parameters influenced the composition distribution of the welds and the penetration depth. The T-peel load of the Cu - Al - Al lap configuration was similar to that of the tensile-shear load.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Review
Optics
Shuai Yan, Zhiyong Li, Linling Song, Yingqiao Zhang, Shouzheng Wei
Summary: The high thermal and electrical conductivity of copper and the low volume density of aluminum make them attractive in the microelectronics industry. However, the high reflectivity and high thermal conductivity between aluminum and copper lead to unstable energy absorptivity and welding process. Laser micro-welding technology has been widely used in the welding of dissimilar metals such as Al and Cu, and various welding parameters and filler materials have been discussed. Good Al-Cu dissimilar joints can achieve similar tensile/shear strength as Al base metals.
OPTICS AND LASERS IN ENGINEERING
(2023)
Article
Materials Science, Multidisciplinary
Eisha Khalid, Vasanth C. Shunmugasamy, Bilal Mansoor
Summary: This study reports the successful micro friction stir welding (mu FSW) between ultra-thin (500 μm) Mg AZ31 and Al 6061-T6 alloy sheets. The process resulted in a defect-free butt weld with refined grains and strong metallurgical interlocking. The joints showed a joint efficiency of 54.5% with respect to the AZ31 base material, and fracture occurred at the interface between the stir zone/thermomechanically affected zone on the Mg advancing side due to intermetallic compounds. These prepared joints have significant potential for structural applications in micro-assemblies and battery packs.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Materials Science, Multidisciplinary
Shun Tokita, Cheng Yi Liu, Yutaka S. Sato
Summary: This study investigates the joining of Al/Cu and Al/Ni dissimilar metals using ultrasonic spot welding. The results show that the vibration amplitude and welding time have a greater impact on joint strength than welding pressure. Optimization of welding parameters allows for high-strength joints that fracture at the Al upper plate. Al/Ni bonding requires a narrower range of welding time to achieve higher tensile shear load compared to other material combinations. Texture analysis reveals recrystallized grains with the GOSS orientation in high-strength dissimilar joints.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
Liang Zhang, Zhengwu Zhu, Xianhui Gao, Fei Yan
Summary: This paper investigates the structural arrangement, grain structure, and texture evolution of a deflected laser welded joint of 304 stainless steel and T2 copper. The fusion zone consists mainly of Fe-Cr-Ni rich alpha structure and minor Cu-rich epsilon structure. The grain size and crystalline orientation vary significantly between the 304 side and the T2 side. In the mixed zone, the epsilon phase exhibits dispersed orientation and fine grains.
MATERIALS CHARACTERIZATION
(2022)
Article
Optics
Xiaolong Cai, Hongmei Li, Bingkui Ji, Mingda Li, Xueping Yao, Yi Wang, Daqian Sun
Summary: Dissimilar welding of TiAl-based alloy and Ni-based superalloy with different single alloying elements (Ti, Nb, V, Cu) using laser was studied. The results showed that laser welding with Ti filler metal was not successful, while welding with Nb filler metal resulted in macrocracks due to the formation of intermetallics. Successful welding was achieved using V and Cu filler metal, forming different solid solutions and eutectic phases in the weld zone, influencing the mechanical properties of the joints.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Optics
Yunfei Meng, Jiangwang Fu, Mengcheng Gong, Shuai Zhang, Ming Gao, Hui Chen
Summary: By using a novel 8-shaped beam oscillation, the uneven heating and reaction at the interface in laser circular oscillating welding of Al/Mg lap-joint with Ti as interlayer were solved, leading to improved connection width and shear tensile force.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Jian Liu, Biao Cao, Jingwei Yang
Summary: This study systematically investigated the microstructure and intermetallic compounds of Cu/Al joints produced by high power ultrasonic welding (HUSW). The research found that the welding time had little effect on the grain morphology and size of pure copper, but had a significant impact on the aluminum alloy. Moreover, the texture characteristics of copper and aluminum alloy also changed during the welding process.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Physics, Condensed Matter
Qinghua Li, Zhibo Dong, Shude Ji, Laishan Yang, Congcong Tao, Shouzhen Zhou, Guangxu Hu
Summary: The weak bonding phenomenon at the joint interface of Al/Cu dissimilar friction stir welding is often induced by unsuitable welding parameters. Factors such as diffusion time, temperature, and pressure play a significant role in affecting the diffusion behavior at the interface. Diffusion time and temperature have a notable impact on diffusion thickness, while external pressure has minimal influence.
PHYSICA STATUS SOLIDI B-BASIC SOLID STATE PHYSICS
(2021)
Article
Materials Science, Multidisciplinary
Huan He, Zhaoxian Liu, Lixin Zhang, Wenzhen Zhao, Ao Fu, Xiaoyang Yi
Summary: The joining of aluminum alloy and Ti-Ni-Hf shape memory dissimilar metals was achieved by cold metal transfer (CMT) welding-brazing with an Al-based filler. The relationship between heat input, microstructures, and joint strength was investigated. The joint consisted of three regions: the Al/SMA brazing interface, weld metal zone, and Al-weld metal zone. The interfacial intermetallic compound (IMC) with a strip or needle-like morphology was identified as TiAl3. The IMC exhibited an inhomogeneous morphology along the brazing interface. The Ti-Ni-Hf SMA adjacent to the interface retained reversible martensitic transformation and its phase transition temperature slightly increased with distance from the interface. Increasing heat input led to an increase in IMC thickness and a decrease in joint strength. The maximum tensile strength achieved was 122 MPa at a heat input of 553.6 J/mm. Fracture initiation occurred at the interface between the IMC and Ti-Ni-Hf and propagated along the interface.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
