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Abstract
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This study investigates the effects of incorporating nickel (Ni) powder in the friction stir lap welding (FSLW) of Aluminum 1050 alloy and commercially pure copper sheets. Both single and multi-pass FSLW techniques were employed, and the mechanical properties and microstructures of the resulting joints were characterized. The addition of Ni powder significantly influenced the morphology, thickness, and type of interfacial intermetallic compounds (IMCs), resulting in the formation of distinct IMC layers, including Al4Cu9 and Al2Cu in samples without Ni, and binary phases such as Al3Ni and Cu3.8Ni in Ni-containing samples. Microstructural analysis revealed refined grain structures, with enhanced refinement observed in multi-pass welding, particularly in samples with Ni powder. Hardness measurements indicated an increase in local mechanical properties due to hard IMCs. The single-pass sample with Ni exhibited the highest tensile load and displacement among the tested samples, attributed to its optimized microstructure and favorable IMC distribution. These findings provide valuable insights into the role of Ni powder in enhancing the performance of dissimilar Al/Cu joints, contributing to advancements in solid-state welding techniques.
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