Micro-Friction Stir Lap Welding of Aluminum and Copper: A Short Review
Received: 19 November 2024 | Revised: 13 January 2025 | Accepted: 18 January 2025 | Online: 17 March 2025
Corresponding author: Chee Kuang Kok
Abstract
This review article examines the recent progress in Micro-Friction Stir Lap Welding (μFSLW) of Al-Cu thin sheets, comparing the differences in tool geometry and processing parameters of macro-scale and micro-scale Friction Stir Lap Welding (FSLW) of Al-Cu plates. The effect of microstructural evolution, intermetallic formation, hardness distribution, mechanical joint strength, and electrical conductivity is discussed in detail. The most common defects in μFSLW, such as voids, tunnel defects, and hook formations, along with their impact on heat input and tool movement, are examined. Additionally, strategies to improve joint quality, including the addition of engineering interlayers (e.g. zinc foil) and nanoparticles (e.g. graphene), are explored as they mitigate brittle IMCs, improve grain structure, and enhance both mechanical and electrical properties. Important research gaps, regarding the effects of tool tilt angles and complex tool profiles on the mechanical and electrical joint properties, are highlighted as the potential benefits of assistive technologies, such as ultrasonic vibration, assistive heating and cooling, and assistive magnetic field. Future work is essential to enhance the μFSLW of Al-Cu, investigating complex tool geometries, and improving process parameters.
Keywords:
aluminium and copper, dissimilar materials, lap joint, micro-friction stir welding, thin sheetsDownloads
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Copyright (c) 2025 Chee Kuang Kok, Kamil Sued, Kia Wai Liew, Moumen Mahmood Jayazerli, Logah Perumal, Lingenthiran Samylingam, Chin Chin Ooi
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