Abstract
Types and distribution of intermetallic compound phases and their effects on the mechanical properties of dissimilar Al/Cu friction stir welded joints were investigated. Three different rotation speeds of 1000, 1200 and 1400 rpm were used with two welding speeds of 20 and 50 mm/min. The results show that the microstructures inside the stir zone were greatly affected by the rotation speed. Complex layered structures that containing intermetallic compound phases such as CuAl
2
, Al
4
Cu
9
were formed in the stir zone. Their amount found to be increased with increasing rotation speed. However, the increasing of the rotation speed slightly lowered the hardness of the stir zone. Many sharp hardness peaks in the stir zones were found as a result of the intermetallic compounds formed, and the highest peaks of 420 Hv were observed at a rotation speed of 1400 rpm. The joints ultimate tensile strength reached a maximum value of 105 MPa at the rotation speed of 1200 rpm and travel speed of 20 mm/min with the joint efficiency ranged between 88 and 96% of the aluminum base metal. At the travel speed of 50 mm/min, the maximum value of the ultimate tensile strength was 96 MPa at rotation speed of 1400 rpm with the joint efficiency ranged between 79 and 90%. The fracture surfaces of tensile test specimens showed no evidence for the effect of the brittle intermetallic compounds in the stir zones on the tensile strength of the joints.