Metallurgical Review of Al-Cu Friction Welded Joints
Abstract
Friction welding of aluminum and copper is a solid-state joining technique widely used in electrical and industrial applications. Significant differences in physical and thermal properties between these metals create challenges at the joint interface. This review focuses on the metallurgical characterization of Al–Cu friction welded joints, emphasizing intermetallic compound (IMC) formation and growth, and the influence of process parameters such as temperature, pressure, friction time, and rotational speed on microstructure and mechanical performance. Excessive IMC layers can cause embrittlement, interfacial cracking, porosity, and reduced thermal stability. Recent advances in process optimization, active cooling, and interface engineering have improved joint strength, ductility, and conductivity. Controlling IMC growth and understanding intermetallic diffusion are crucial for producing reliable Al-Cu joints. This review summarizes current strategies for enhancing the mechanical performance of Al–Cu friction welded joints.
##Keywords:##
Al-Cu; Friction Welding; Intermetallic Compounds; Joint Strength; Metallurgical Characterization.
Published
Mar 30, 2026
How to Cite
SALMAN, Nidya Jullanar.
Metallurgical Review of Al-Cu Friction Welded Joints.
Journal of Ocean, Mechanical and Aerospace -science and engineering-, [S.l.], v. 70, n. 1, p. 13-24, mar. 2026.
ISSN 2527-6085.
Available at: <https://www.isomase.org/Journals/index.php/jomase/article/view/581>. Date accessed: 29 may 2026.
doi: http://dx.doi.org/10.36842/jomase.v70i1.581.
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[19] Hendrato, Puspitasari, P., Jamasri & Triyono. (2024). Fatigue crack growth rate and mechanical properties of one-step double-side friction stir welded AA6061-T6. Results in Engineering, 21, 101958.
[20] Smolin, A. Y., Shilko, E. V., Astafurov, S. V., Kolubaev, E. A., Eremina, G. M. & Psakhie, S. G. (2018). Understanding the mechanisms of friction stir welding based on computer simulation using particles. Defence Technology, 14(6), 643–656.
[21] Mothilal, M. & Kumar, A. (2024). Optimization of friction stir welding process parameter in the joining of AA7075-T6/AA5083-O dissimilar aluminum alloy using response surface methodology. International Journal of Pressure Vessels and Piping, 211, 105282.
[22] Zhou, N., Gan, C., Song, D., Qi, W. & Attallah, M. M. (2019). Influence of forging pressure on microstructural and mechanical properties development in linear friction welded Al-Cu dissimilar joint. Soldagem e Inspeção, 24, 1–7.
[23] Wei, Y., Li, J., Xiong, J. & Zhang, F. (2016). Investigation of interdiffusion and intermetallic compounds in Al–Cu joint produced by continuous drive friction welding. Engineering Science and Technology, an International Journal, 19(1), 90–95.
[24] Habba, M. I. A, & Ahmed, M. M. Z. (2025). Friction stir welding of dissimilar aluminum and copper alloys: A review of strategies for enhancing joint quality. Journal of Advanced Joining Processes, 11, 100293.
[25] Zobac, O., Kroupa, A., Zemanova, A. & Richter, K. W. (2019). Experimental description of the Al-Cu binary phase diagram. Metallurgical and Materials Transactions A, 50(8), 3805–3815.
[26] Jia, Y., Ji, P. & Shi, X. (2020). Solidification of Al-xCu alloy under high pressures. Journal of Materials Research and Technology, 9.
[27] Suzuki, T., Yabe, T., Enoki, M. & Ohtani, H. (2025). Thermodynamic investigation of Guinier–Preston zone formation in the Al–Cu binary system. Scripta Materialia, 265, 116746.
[28] Al, L., Bimetalnega, C., Mila, V. D., Radovanovi, R. V., Mila, M. D. & Gligorijevi, B. R. (2016). Effects of friction-welding parameters on the morphological properties of an Al/Cu bimetallic joint. Materiali in Tehnologije, 50(1), 89–94.
[29] Zhang, S., Xie, F., Wu, X., Luo, J., Li, W. & Yan, X. (2023). The microstructure evolution and mechanical properties of rotary friction welded duplex stainless-steel pipe. Materials, 16(9).
[30] Dahlan, H., Nasution, A. K., Zuhdi, S. A. & Rusli, M. (2023). Study of the effect of friction time and preheating on the joint mechanical properties of friction welded SS 316-pure Zn. Applied Sciences, 13(2).
[31] Dhamothara Kannan, T., Sivaraj, P., Balasubramanian, V., Malarvizhi, S., Sonar, T., Ivanov, M. & Sathiya, S. (2023). Joining different grades of low carbon steel to develop unsymmetrical rod to plate joints using rotary friction welding for automotive applications. Forces in Mechanics, 10, 100153.
[32] Kah, P., Vimalraj, C., Martikainen, J. & Suoranta, R. (2015). Factors influencing Al-Cu weld properties by intermetallic compound formation. International Journal of Mechanical and Materials Engineering, 10(1).
[33] Aghajani Derazkola, H., García, E., Eyvazian, A. & Aberoumand, M. (2021). Effects of rapid cooling on properties of aluminum-steel friction stir welded joint. Materials, 14(4), 1–17.
[34] Ary, D., Muhayat, N. & Triyono. (2023). Research gap finding in shielded metal arc welding of steel. E3S Web of Conferences, 465, 1–7.
[35] Sauter, L., Werz, M. & Weihe, S. (2025). Continuous drive friction welding of commercial pure aluminum to copper: Metallographic and mechanical characterization of various cross-sections. Journal of Advanced Joining Processes, 12, 100342.
[36] Ratkovi, N. R. (2017). Influence of friction welding parameters on properties of the Al-Cu joint. FME Transactions, 45, 165–171.
[37] Dang, Z., Qin, G. & Li, T. (2023). Microstructure evolution and tensile strength of Al/Cu inertia friction welded joint. Journal of Materials Research and Technology, 27, 4023–4031.
[38] Wei, Y., Li, J., Xiong, J. & Zhang, F. (2016). Investigation of interdiffusion and intermetallic compounds in Al–Cu joint produced by continuous drive friction welding. Engineering Science and Technology, an International Journal, 19(1), 90–95.
[39] Ahmed, G. M. S., Algahtani, A., Mahmoud, E. R. I. & Badruddin, I. A. (2018). Experimental evaluation of interfacial surface cracks in friction welded dissimilar metals through image segmentation technique. Materials, 11, 2460.
[40] Yashwant, C., Dinesh, K. & Salim, S. S. (2020). Friction welding of aluminium alloy 6063 with copper. E3S Web of Conferences, 170, 2–7.
[41] Fuse, K., Badheka, V., Oza, A. D., Prakash, C., Buddhi, D., Dixit, S., & Vatin, N. I. (2022). Microstructure and mechanical properties analysis of Al/Cu dissimilar alloys joining by using conventional and bobbin tool friction stir welding. Materials, 15(15).
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