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Friction welding of aluminum alloys to copper was carried out in order to examine the weldability with particular reference to the effect of the intermetallic formation at the weld interface. The maximum joint efficiencies of A1050, 5000 and 6000 series alloys to copper were more than 80 %, while those of 2000 series and A7075 alloys joints were less than 50 % and scattered widely. For joints of A2024 and 5000 series alloys which contain rather high magnesium content, intermetallic compounds of Al-Cu-Mg system were formed at the weld interface in addition to that of Al-Cu system. In the other joints, only intermetallic compounds of Al-Cu system were formed. A mixing layer, in which pieces of copper and intermetallic compounds were incorporated into aluminum alloy, was formed near the weld interface. The mixing was very intense, in the joints with low efficiency, namely joints of A2011, A2024 and A7075 to copper, and these joints were fractured in this mixing layer and at the weld interface. On the other hand, the joints with high efficiency, namely joints of A5052 and A6061 to copper, had thin and even mixing layer. The mixing layers observed in the joints of A1050, A2017, A5056 and A6063 to copper were thinner than those of the other joints.

Formation of Intermetallic Compounds in Friction-Welded Joint of Aluminum Alloys to Copper and its Influence on Joint Efficiency