Upset-resistance welding of aluminium to copper rods: effect of interface on performance

ABSTRACT

Upset resistance dissimilar welding of aluminium and copper narrow rods was performed. Effect of the interface characteristics was studied on the joint mechanical and electrical properties. Upset resistance welding (URW) was successful for production of joints with high strength and electrical conductivity between aluminium and copper rods. Reaction layer at the joint interface was composed of the Al₂Cu cellular phase and lamellar eutectic structure of α-Al and Al₂Cu. Enhancement of the welding current and decrease in the upset force increased the reaction layer thickness and strength of the joint. URW had no significant detrimental effect on the electrical conductivity of the weld zone. Neither the joint strength nor the joint electrical conductivity was improved by in situ post weld heat treatment.

KEYWORDS:

• Upset resistance welding
• aluminium
• copper
• strength
• electrical resistance
• post weld heat treatment
• microstructure
• solid state welding

Disclosure statement

No potential conflict of interest was reported by the authors.