Skip to main content
SpringerLink
Log in

Effect of Silicon Content in Al–Si Welding Wire on Mechanical Properties of Al/Cu Laser Welded Joint

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

In this study, the laser welding of Al/Cu using Al–Si welding wires was analyzed. The impact of varying silicon content in the Al–Si welding wires (0%, 12%, 16%, 20%) and laser power settings ranging from 900 to 1050W in 50W increments on the phase composition, microstructure, and mechanical properties of the weld joints was investigated. It was observed that a silicon-rich interface layer formed near the copper side of the weld seam. This formation led to grain orientation and a significant reduction in grain size. As the Si content increased, the morphological structure transformed from irregularly layered dendritic to regularly oriented dendritic, and ultimately to equiaxed crystals. X-ray diffraction analysis of the weld seam revealed the presence of main intermetallic phases, including Al2Cu. It was concluded that the highest tensile strength, reaching 85.1 MPa, was achieved using an AlSi12 weld filler at a power of 900W.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. Schmalen, P., & Plapper, P. (2016). Evaluation of laser braze-welded dissimilar Al–Cu joints. Physics Procedia, 83, 506–514. https://doi.org/10.1016/j.phpro.2016.08.052

    Article  Google Scholar 

  2. Li, Q., Zhu, B., Li, H., et al. (2023). Effect of spiral scan distance on the nanosecond-pulsed-laser lap joint of Al/Cu. Optics & Laser Technology, 158, 108896. https://doi.org/10.1016/j.optlastec.2022.108896

    Article  Google Scholar 

  3. Chen, T., Liu, F., Pang, L., et al. (2023). Microstructure and performance study of Al/Cu Laser welding with Ag interlayer. International Journal of Precision Engineering and Manufacturing. https://doi.org/10.1007/s12541-023-00921-5

    Article  Google Scholar 

  4. Zhou, L., Li, Z. Y., Song, X. G., et al. (2017). Influence of laser offset on laser welding-brazing of Al/brass dissimilar alloys. Journal of Alloys and Compounds, 717, 78–92. https://doi.org/10.1016/j.optlastec.2017.08.004

    Article  Google Scholar 

  5. Zhou, L., Luo, L. Y., Tan, C. W., et al. (2018). Effect of welding speed on microstructural evolution and mechanical properties of laser welded-brazed Al/brass dissimilar joints. Optics & Laser Technology, 98, 234–246. https://doi.org/10.1016/j.optlastec.2017.08.004

    Article  Google Scholar 

  6. You, J., Zhao, Y., Dong, C., et al. (2023). Improving the microstructure and mechanical properties of Al-Cu dissimilar joints by ultrasonic dynamic-stationary shoulder friction stir welding. Journal of Materials Processing Technology, 311, 117812. https://doi.org/10.1016/j.jmatprotec.2022.117812

    Article  Google Scholar 

  7. You, J., Zhao, Y., Dong, C., et al. (2022). Microstructural evolution and mechanical properties of the Al–Cu dissimilar joint enhanced by stationary-dynamic shoulder friction stir welding. Journal of Materials Processing Technology, 300, 117402. https://doi.org/10.1016/j.jmatprotec.2021.117402

    Article  Google Scholar 

  8. Bagheri, B., Alizadeh, M., Mirsalehi, S. E., et al. (2022). Nanoparticles addition in AA2024 aluminum/pure copper plate: FSSW approach, microstructure evolution, texture study, and mechanical properties. JOM Journal of the Minerals Metals and Materials Society, 74(11), 4420–4433. https://doi.org/10.1007/s11837-022-05481-z

    Article  Google Scholar 

  9. Abdollahzadeh, A., Bagheri, B., & Shamsipur, A. (2023). Development of Al/Cu/SiC bimetallic nano-composite by friction stir spot welding. Materials and Manufacturing Processes, 38(11), 1416–1425. https://doi.org/10.1080/10426914.2022.2157435

    Article  Google Scholar 

  10. Bagheri, B., Abdollahzadeh, A., & Shamsipur, A. (2023). A different attempt to analysis friction stir spot welding of AA5083-copper alloys. Materials Science and Technology, 39(9), 1083–1089. https://doi.org/10.1080/02670836.2022.2159633

    Article  Google Scholar 

  11. Bagheri, B., Alizadeh, M., Mirsalehi, S. E., et al. (2022). The effect of rotational speed and dwell time on Al/SiC/Cu composite made by friction stir spot welding. Welding in the World, 66(11), 2333–2350. https://doi.org/10.1007/s40194-022-01376-4

    Article  Google Scholar 

  12. Bagheri, B., Shamsipur, A., Abdollahzadeh, A., et al. (2023). Investigation of SiC nanoparticle size and distribution effects on microstructure and mechanical properties of Al/SiC/Cu composite during the FSSW process: experimental and simulation. Metals and Materials International, 29(4), 1095–1112. https://doi.org/10.1007/s12540-022-01284-8

    Article  Google Scholar 

  13. Vaneghi, A. H., Bagheri, B., Shamsipur, A., et al. (2022). Investigations into the formation of intermetallic compounds during pinless friction stir spot welding of AA2024-Zn-pure copper dissimilar joints. Welding in the World, 66(11), 2351–2369. https://doi.org/10.1007/s40194-022-01366-6

    Article  Google Scholar 

  14. Zhu, B., Zhen, L., Xia, H., et al. (2021). Effect of the scanning path on the nanosecond pulse laser welded Al/Cu lapped joint. Optics & Laser Technology, 139, 106945. https://doi.org/10.1016/j.optlastec.2022.108896

    Article  Google Scholar 

  15. Dimatteo, V., Ascari, A., & Fortunato, A. (2021). Dissimilar laser welding of copper and aluminum alloys in multilayer configuration for battery applications. Journal of Laser Applications. https://doi.org/10.2351/7.0000476

    Article  Google Scholar 

  16. Yan, S., & Shi, Y. (2019). Influence of laser power on microstructure and mechanical property of laser-welded Al/Cu dissimilar lap joints. Journal of Manufacturing Processes, 45, 312–321. https://doi.org/10.1016/j.jmapro.2019.07.009

    Article  Google Scholar 

  17. Liu, J., & Cao, B. (2021). Microstructure characteristics and mechanical properties of the Cu/Al dissimilar joints by electric current assisted ultrasonic welding. Journal of Materials Processing Technology, 297, 117239. https://doi.org/10.1016/j.jmatprotec.2021.117239

    Article  Google Scholar 

  18. Cheng, X. M., Yang, K., Wang, J., et al. (2023). Ultrasonic welding of Cu to Al cables bonding: Evolution of microstructure and mechanical properties. Materials Characterization, 200, 112905. https://doi.org/10.1016/j.matchar.2023.112905

    Article  Google Scholar 

  19. Go, B.-S., Kim, K.-H., Ro, C.-S., et al. (2022). Influence of process parameters on formation of Al/Cu dissimilar weld using ultrasonic welding. International Journal of Precision Engineering and Manufacturing, 23(12), 1359–1365. https://doi.org/10.1007/s12541-022-00651-0

    Article  Google Scholar 

  20. Li, Y., Huang, J., Yang, N., et al. (2023). Interfacial reaction and microstructure evolution of nanoparticle-added Al/Cu welded interface under direct current treatment. Materials Today Communications, 34, 105327. https://doi.org/10.1016/j.mtcomm.2023.105327

    Article  Google Scholar 

  21. Tang, J., Shi, L., Wu, C., et al. (2023). Development of novel double-side friction stir Z shape butt-lap welding process for dissimilar joining of 12 mm medium-thick Al/Cu plates. Materials Letters, 331, 133445. https://doi.org/10.1016/j.matlet.2022.133445

    Article  Google Scholar 

  22. Kumar, S., Katiyar, J. K., & Roy, B. S. (2023). Influence of tool tilt angle on physical, thermal, and mechanical properties of friction stir welded Al-Cu-Li alloys. Materials Today Communications, 34, 105348. https://doi.org/10.1016/j.mtcomm.2023.105348

    Article  Google Scholar 

  23. Ji, S., Zhang, Z., Gong, P., et al. (2022). Microstructural formation and mechanical performance of friction stir double-riveting welded Al-Cu joints. Chinese Journal of Aeronautics. https://doi.org/10.1016/j.cja.2022.11.010

    Article  Google Scholar 

  24. Kang, J.-W., Zhang, S., Bui Thi, T.-A., et al. (2023). Friction-assisted dissimilar solid state lap joining of aluminum and copper pipes. International Journal of Precision Engineering and Manufacturing, 24(2), 199–208. https://doi.org/10.1007/s12541-022-00745-9

    Article  Google Scholar 

  25. Yan, S., Li, Z., Song, L., et al. (2023). Research and development status of laser micro-welding of aluminum-copper dissimilar metals: A review. Optics and Lasers in Engineering. https://doi.org/10.1016/j.optlaseng.2022.107312

    Article  Google Scholar 

Download references

Acknowledgements

This work was supported by the National Natural Science Youth Foundation of China (No. 51704092)

Author information

Authors and Affiliations

  1. College of Materials Science and Engineering, Hefei University of Technology, Hefei, 230001, China

    Peifeng Wang, Fei Liu, Lihui Pang & Zhe Guo

Authors
  1. Peifeng Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fei Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Lihui Pang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zhe Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Fei Liu.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, P., Liu, F., Pang, L. et al. Effect of Silicon Content in Al–Si Welding Wire on Mechanical Properties of Al/Cu Laser Welded Joint. Int. J. Precis. Eng. Manuf. 25, 1063–1071 (2024). https://doi.org/10.1007/s12541-023-00949-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-023-00949-7

Keywords

Search

Navigation