Linear friction welding of aluminium to copper

The joining of dissimilar materials is attaining increasing importance as there is a drive to utilise hybrid structures and reduce the weight or cost of products. The present work therefore studied the linear friction welding of commercially pure grades of aluminium to copper (AA 1050 to C101) for potential power transmission applications. Results showed that welds with very good mechanical and electrical properties can be produced. The weld microstructure was analysed using optical microscopy, backscattered scanning electron microscopy, hardness testing and high energy synchrotron X-ray diffraction. These techniques were used in order to identify any cross-weld grain size variations and possible formation of intermetallic phases close to the weld line.