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The relationship between joint strength and deformation heat input at the upset stage and the relationship between joint strength and upset bum-off length were examined on friction welded joints of 1050 pure aluminum to C1100 tough pitch copper. Joint quality was evaluated from the tensile strength and fatigue strength. It was found that both the deformation heat input at the upset stage and the upset burn-off length correlated well with joint strength. Additionally, when the deformation heat input at the upset stage or upset burn-off length exceeded a certain value, stable tensile strength was obtained. The mixing layer, intermetallic compounds of Al-Cu were interpolated into A1050, formed at the weld interface, and joints having a thick mixing layer fractured at the weld interface. Joint efficiencies of sound joints for the fatigue limit of the A1050 base metal were 88-100%. Judging from the fatigue limit, sound joints could be produced when either the deformation heat input at the upset stage or the upset burn-off length exceeded a certain value.

Evaluation of Tensile Strength and Fatigue Strength of Commercial Pure Aluminum/Tough Pitch Copper Friction-Welded Joints by Deformation Heat Input