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J. Mater. Sci. Technol., 2013, -(-), 1e9

Microstructure and Mechanical Properties in Dissimilar Butt Friction Stir

Welding of Severely Plastic Deformed Aluminum AA 1050 and Commercially
Pure Copper Sheets
H. Barekatain, M. Kazeminezhad*, A.H. Kokabi
Department of Materials Science and Engineering, Sharif University of Technology, Azadi Avenue, Tehran, Iran
[Manuscript received March 2, 2013, in revised form April 15, 2013, Available online xxx]

In this study, AA 1050 aluminum alloy and commercially pure copper in annealed and severely plastic deformed
conditions were used. The technique used for imposing the severe strain to the sheets was constrained groove
pressing (CGP) process. The annealed and severely plastic deformed sheets were subjected to friction stir
welding (FSW) at different rotation and traverse speeds. Cu was placed in advancing side. Constant offset of
approximately 1 mm was used toward Al side for all welds. A range of welding parameters which can lead to
acceptable welds with appropriate mechanical properties was found. For the FSWed CGPed samples, it was
observed that the welding heat input caused grain growth and decrease in hardness value at Al side of the
stir zone. It was found that, generally the weakest parts of weld joints of annealed and CGPed samples were
Al base metal and stir zone, respectively. Further investigations showed that several forms of intermetallic
compounds were produced.

KEY WORDS: Friction stir welding; Severe plastic deformation; Aluminum; Copper; Intermetallics

1. Introduction process to obtain UFGed structure and reported signicant grain

Lots of efforts have been focused on producing ultra-ne
grained (UFGed) materials during last decade due to their su-
perior mechanical properties. Severe plastic deformation (SPD)
is a prominent way to produce UFGed materials. Two main SPD
processes of sheets are accumulative roll bonding (ARB) and
constrained groove pressing (CGP)[1,2]. It is reported that ARB
has some limitations to SPD of sheet metals[3]. In CGP process,
SPD can be imposed to sheet metals by means of pressing in
grooved and at dies, alternatively[4]. The size of SPDed sheets
is limited due to restriction in load capacity and equipments, so
less industrial application can be found. Joining is the best so-
lution for this problem[5]. Conventional welding processes are
useless for joining SPDed metals, because of deteriorating me-
chanical properties of weld zone due to grain coarsening[5,6].
Previous investigations[6e9] imply that friction stir welding
(FSW) is one of the best methods to join UFGed materials. Sun
et al.[5] examined the effect of initial grain size on the joint
properties of friction stir welded 1050-Al alloy. They used ARB
*
Corresponding author. Prof., Ph.D.; Tel.: 98 21 66165227; Fax: 98
21 66005717; E-mail address: mkazemi@sharif.edu (M. Kazeminezhad).
1005-0302/$ e see front matter Copyright 2013, The editorial ofce of
Journal of Materials Science & Technology. Published by Elsevier
Limited. All rights reserved.
http://dx.doi.org/10.1016/j.jmst.2013.11.007
growth and corresponding decrease in hardness of the stir zone.
Topic et al.[9] probed the microstructures and mechanical prop-
erties of ARBed AA 1050 and AA 6016 aluminum sheets after
FSW process. They observed softening in the stir zone of
weldments. In the most recent research, Khorrami et al.[6]
analyzed the mechanical properties of SPDed Al sheets joined
by FSW. They used CGP process for imposing severe strain to
sheets. They investigated the microstructures and mechanical
properties of SPDed Al after FSW and compared them with the
results achieved from FSW of annealed ones.
FSW is an innovative solid state joining process that has been
proven to be an effective way for joining materials with poor
fusion weldability such as dissimilar materials[10]. There are a
few studies on joining of SPDed Al alloys sheet metals, however,
to our knowledge no studies have evaluated dissimilar joining of
SPDed Al and Cu sheet metals. Although some experiments in
FSW of Al to Cu have been reported, no successful results have
been yet achieved and there are some issues that still require
investigations[11e19]. Cu and Al are not compatible metals and
both of them have limited solubility in the solid state, so it leads
to form several intermetallic compounds (IMCs). Ouyang
et al.[13] worked on FSW of 6061 aluminum alloys to pure
copper sheets with 12.7 mm thickness. They reported that the
mechanically mixed region in weld stir zone consists of CuAl2,
CuAl and Cu9Al4, and because of the brittle nature of these
IMCs, direct FSW of 6061 Al to copper is difcult. Galvo

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Table 1 Summary of previous studies on FSW of Al and Cu sheets

No. Sheet metals Thickness Welding parameters Offset (mm) Tool parameters Ref.
(mm)
Rotation Traverse Tilt angle Pin diameter Shoulder
speed (r/min) speed (mm/min) (deg.) (mm) diameter (mm)

1 Al 1060/Cu (Aa) 5 600 100 e 2 6 20 [15]

2 Al 6061/Cu 12.7 914 95 e e 12 e [13]
3 Al 2024/Cu e 650 60 e e e e [12]
4 Al 1100/Cu (A) 4 1430 90 2.5 1.5 4 20 [11]
5 Al 6061/Cu (A) 6 650 60 e e 6.5 e [12]
6 Al 5A06/Cu 3 950 150 e e e e [29]
7 Al 1350/Cu (A) 2 1000 80 2.5 2 5.2 16 [22]
8 Al 1050/Cu (A) 4 900 100 e e e e [25]
9 Al 5052/Cu (A) 3 1000 100 2.5 0 3 12 [19]
a
A means advancing side.

Table 2 Chemical composition of used materials (wt%)

Materials Al Fe Si Zn Pb Ni Cu

AA 1050 Bal. 0.30 0.07 0.005 0.003 <0.001 0.005

Commercially pure copper 0.02 0.05 0.009 0.3 0.03 0.03 Bal.

et al.[16,18] investigated inuence of process parameters and
shoulder geometry on formation and distribution of brittle
compounds in FSW of aluminum and copper.
There are many process parameters, such as rotation speed,
traverse speed and tool offsetting that inuence the weld prop-
erties of the dissimilar FSW joints. Recently, it is well docu-
mented that during FSW of dissimilar material, the harder
material should be placed in advancing side. It is also reported
that during the FSW of dissimilar materials, the tool pin should
have a constant offset toward the softer material[20]. For instance,
Xue et al.[17] achieved defect-free welds between 1060
aluminum and commercially pure copper by using the tool pin
offset toward aluminum. A brief summary of all previous studies
on dissimilar FSW of Al and Cu alloys is illustrated in Table 1. It
is obvious that there is no unanimous agreement on welding
parameters, which can make defect-free joints, and a wide range
for rotation and traverse speeds have been reported.
In this study, AA 1050 aluminum alloy and commercially pure
copper in annealed and CGPed conditions were subjected to butt
FSW. The mechanical properties and microstructures of FSWed
specimens were investigated. The aim of this study is to nd a
range of welding parameters and subsequently a range of heat
input, which can produce acceptable welds with appropriate
mechanical properties for both annealed and CGPed samples.
2. Experimental
AA 1050 aluminum and commercially pure copper sheets
with dimension of 84 mm  50 mm  3 mm were used. Table 2
shows the chemical composition of these materials. Al and Cu
sheets were annealed at 350  C and 650  C, respectively. Some
of the Al and Cu sheets were subjected to CGP process. In each
pass of this process effective strain of 1.16 was imposed to the
sheet[21]. In this study specimens were subjected to 2 passes of
CGP process. The mechanical properties of used materials before
welding process can be seen in Table 3.
FSW machine was used to dissimilar butt weld of the samples
in annealed and 2 passes CGPed conditions. Welding tool had
15 mm-diameter shoulder and 3 mm-diameter pin, which was
made from H13 tool-steel. The tilt angle of the tool was 2.5 . Cu,
which was the harder material, was placed in advancing side and
the tool pin had constant offset about 1 mm toward the Al side.
FSW was conducted at rotation speeds of 600, 800, 900, 1000,
1200 and 1400 r/min, and traverse speeds of 50, 63, 80, 100 and
125 mm/min. For microstructure analysis, transversal sections of
welds were prepared and chemically etched to reveal the
microstructure of different zones. Al side of the welds was
electro-etched by 10 ml HBF4 200 ml distilled water at a
voltage of 26 V for 80 s and grain structure was revealed by
using polarized light. Afterward, the copper side was etched with
a solution of 5 g FeCl2 50 ml HCl 100 ml H2O. Scanning
electron microscopy (SEM) complemented by energy dispersive
X-ray spectroscopy (EDS) was also used in order to examine the
more delicate structure formed in the stir zone.
To evaluate mechanical properties of the specimens after FSW
process, transverse tensile and microhardness prole tests were
performed. According to the ASTM E8M standard, three tensile
specimens were cut from the mid-length of the welds. Tensile
tests were carried out using an Instron machine operating at a
speed of 1 mm/min. The Vickers microhardness test was carried
out on the centerline of cross-section perpendicular to the
welding direction, using 1 N load for 15 s.
3. Results and Discussion
3.1. Selection of appropriate heat-input range
According to Table 1, previous studies on FSW of Al to Cu do
not show unanimous agreement of suitable welding parameters.
Therefore, in this study, wide ranges of rotation speeds from 600
Table 3 Mechanical properties of used materials
Mechanical Annealed Al CGPed Al Annealed Cu CGPed Cu
properties
UTS (MPa) 72 115 210 300
Hardness (HV) 25 45 57 93

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Fig. 1 Weld surface of specimen at rotation speed of 800 r/min and
traverse speed of 80 mm/min.
to 1400 r/min, and traverse speeds of 50e125 mm/min were
chosen. It was observed that traverse speed range of 50e
100 mm/min and rotation speeds of more than 900 r/min produce
welds with appropriate surface in annealed sample. In rotation
speeds less than 900 r/min, weld surfaces contain lots of voids,
and no successful joints are achieved, because these rotation
speeds cannot provide enough heat input for producing sound
joints. For example in Fig. 1, the weld surface of a specimen at
rotation speed of 800 r/min and traverse speed of 80 mm/min can
be seen. The weld has poor surface quality with several voids.
Rotation speed of more than 1000 r/min produces welds with
appropriate surface in CGPed samples. This may result from
higher strength of CGPed ones that required higher heat input.
Traverse speed of 125 mm/min cannot produce sound weld
surfaces in all rotation speeds from 600 to 1400 r/min, either.
Therefore, best rotation speed and traverse speed ranges are
1200e1400 r/min and 50e100 mm/min, respectively. Fig. 2
shows welds surfaces of specimens subjected to the aforemen-
tioned welding parameters. Some of these weld surfaces have
small voids, but generally they have acceptable appearance.
Fig. 2 Surface morphologies of AleCu FSW joints in annealed and CGPed conditions at different welding parameters, with constant pin offset of
approximately 1 mm.
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Results of tensile tests are presented in Table 4. In this table,
the welding parameters were sorted by ratio of rotation speed to
traverse speed (u/V); this ratio is used as a criterion of heat input
in this study. In this table, the average of ultimate tensile strength
(UTS) and place of fracture of weld joints can be seen. Most of
the annealed samples are fractured from Al base metal (BM),
because during FSW the materials in the stir zone were exposed
to severe plastic deformation, which caused a very ne grain
structure in the weld region in comparison to that of Al base
metal and consequently it leads to higher hardness value and
strength. Furthermore, according to Table 3, the UTS of Al base
metal is less than that of Cu base metal; therefore, most of
specimens are fractured from Al base metal. Li et al.[22] reported
similar results. Regarding Table 4, most of CGPed samples are
fractured from stir zone and some of them are fractured from heat
affected zone (HAZ) in Al side. These phenomena occurred
because of higher strength of CGPed sheets. It shows that the
strength of stir zone is lower than that of base metals, especially
Al base metal. In Fig. 3, the macro images of selected fractured
samples can be seen.
As previously mentioned, the aim of this study was to nd a
range of heat input, in which the acceptable weld properties
in both annealed and CGPed samples can be achieved. For
this purpose, further microstructural investigations were carried
out. Fig. 4 shows microstructures of joints at different welding
parameters. Most of the joints have defects, such as voids
and cracks; but there are some defect-free joints. Considering
Fig. 2, Table 4 and Fig. 4, it is inferred that welding parameters
of 1400 r/mine80 mm/min, 1200 r/mine63 mm/min and
4 H. Barekatain et al.: J. Mater. Sci. Technol., 2013, -(-), 1e9

Table 4 UTS and place of fracture of AleCu FSW joints in annealed and CGPed conditions at different welding parameters, with constant pin offset of
approximately 1 mm

Welding parameters u/V ((r/min)/(mm/min)) Annealed (MPa) Place of fracture (for annealed) CGPed (MPa) Place of fracture
(for CGPed)

1200 r/mine100 mm/min 12 68 Al base 44 Stir zone

1400 r/mine100 mm/min 14 36 Al base 69 Stir zone
1200 r/mine80 mm/min 15 53 Stir zone-TMAZ 63 Stir zone
1400 r/mine80 mm/min 17.5 72 Al base 81 Al HAZ
1200 r/mine63 mm/min 19.05 61 Stir zone 80 Al HAZ
1400 r/mine63 mm/min 22.22 70 Al base 78 Al HAZ
1200 r/mine50 mm/min 24 68 Al base 59 Stir zone
1400 r/mine50 mm/min 28 66 Stir zone 21 Stir zone

1400 r/mine63 mm/min are the best parameters; because their
correlate weldments have not only higher comparable UTS,
but also they have the least weld defect and in some cases no
defects. For example annealed samples at welding parameters of
1200 r/mine63 mm/min and CGPed samples at welding pa-
rameters of 1400 r/mine63 mm/min do not have any defects.
As can be seen in Table 4, the aforementioned welding pa-
rameters have a specic u/V range, from 17.5 to 22.22 (r/min)/
(mm/min). Therefore, it can be realized that comparatively
acceptable FSWed joints between Al and Cu, in annealed and
CGPed conditions, can be achieved with aforementioned u/V
ratio range. It also can be understood that welding parameters
with u/V ratio of higher than 22.22 (r/min)/(mm/min) and less
than 17.5 (r/min)/(mm/min), cannot provide comparatively
acceptable joints; because they produce higher and lesser heat-
input values, respectively, than what is needed to have accept-
able joints in annealed and CGPed samples.

3.2. Microstructure of FSW joints

The microstructures of initial materials can be seen in Fig. 5.

Fig. 3 Macro images of fractured samples: (a) in CGPed condition at
welding parameters of 1400 r/min and 50 mm/min, (b) in CGPed
condition at welding parameters of 1400 r/min and 80 mm/min,
(c) in annealed condition at welding parameters of 1400 r/min
and 80 mm/min.
During CGP process, a great deal of grain renement can
occur[4,23]. For example, Hosseini and Kazeminezhad[4] reported
that after 2 passes of CGP process, grain size of Al is decreased
to 0.9 mm. It is also reported by Krishnaiah et al.[24] that after 3
passes of CGP process, grain size of Cu is decreased to 0.5 mm.
The macrostructure of FSW joint of annealed sample at
welding parameters of 1200 r/mine63 mm/min can be seen in

Fig. 4 Cross-sectional microstructures of the AleCu joints at different welding parameters.

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Fig. 5 Microstructures of initial materials: (a) annealed Al, (b) annealed Cu.
Fig. 6, in which no defect such as void can be found. The stir
zone consists of a detached Cu layer, surrounded by Al.
Considering Fig. 7(a), it can be observed that the average
grain size in the stir zone is ner than that in the base metal. This
grain renement during FSW process leads to greater hardness in
the stir zone in comparison with hardness of Al base metal,
which can be seen in Fig. 8. Regarding Fig. 7(a), elongated
grains in TMAZ (thermo-mechanical-affected zone) of Cu which
can be observed in TMAZ of Al, cannot be seen. This phe-
nomenon is in line with previous studies[2,25].
Fig. 6 Macrostructure of weld joint of annealed samples at u
1200 r/min and V 63 mm/min.
Fig. 7 Microstructure of TMAZ of weld joint of annealed samples at
u 1200 r/min and V 63 mm/min: (a) at Al side and (b) at Cu
side.
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The microhardness prole of FSW joint of annealed samples
at welding parameters of 1200 r/mine63 mm/min is presented in
Fig. 8. The hardness value of stir zone is higher than that of Al
base metal, because the materials in the stir zone are exposed to
SPD and subsequent recrystallization[2], which caused a very
ne grain structure in the weld region (Fig. 7(a)). The hardness
value of stir zone is higher than that of Al base metal caused by
grain renement; but this hardness value is lower than that of Cu
base metal.
Fig. 9 shows the SEM backscattered electron images (BEI) of
FSWed CGPed sample at welding parameters of u 1200 r/min
and V 63 mm/min. As shown in Fig. 9(a), the stir zone consists of
a mixture of aluminum matrix and Cu particles. Some voids can
also be observed in this image. Fig. 9(b) shows a magnied view of
the rectangular region in Fig. 9(a), and Fig. 9(c) shows a contin-
uous intermetallic layer in AleCu interface. Intermetallic com-
pounds are seen in different forms in the stir zone. The rst type of
these compounds is in form of membranes encircling Cu particles
(layer A), which have been dispersed through the stir zone during
FSW. According to EDS analysis of phases shown in Fig. 10, this
layer consists of Al4Cu9. This intermetallic compound is always
surrounded by another intermetallic compound (layer B). EDS
analysis reveals that the ratio of aluminum atoms to copper is about
1.85. It suggests that this layer is Al2Cu. It is obvious that layer B
contains more Al than layer A. According to the AleCu binary
equilibrium phase diagram[26], there are various intermetallic
compounds, involving Al2Cu, AlCu, Al3Cu4 and Al4Cu9, which
may be developed during the Al/Cu reaction. Xue et al.[15] have
observed AlCu in AleCu stir zone. On the contrary, AlCu is not
observed in the present study. This fact is in fully agreement with
data reported for dissimilar FSW of Al and Cu[13,25,27], where
Al2Cu and Al4Cu9 are the most probable intermetallic compounds
that can be developed in the stir zone. Another type of these
compounds is formed as a continuous and uniform layer (layer C)
Fig. 8 Microhardness proles of annealed samples subjected to FSW at
u 1200 r/min and V 63 mm/min.
6 H. Barekatain et al.: J. Mater. Sci. Technol., 2013, -(-), 1e9

Fig. 9 SEM backscattered electron images (BEI) of the CGPed Al and Cu samples FSWed at u 1200 r/min and V 63 mm/min: (a) cross-sectional
macrograph of the joint, (b) magnied view of the rectangular region in (a), and (c) microstructure of the AleCu interface.

in AleCu interface with a thickness of about 0.6 mm. Considering side is lower than that of Al base metal, which may be due to
XRD results of AleCu interface, Xue et al.[15] reported that this grain growth in HAZ leading to lower UTS.
layer is composed of Al2Cu and Al4Cu9. Fig. 13 shows the SEM BEIs of FSWed annealed samples at
Fig. 11 shows the microstructure of stir zone of the FSWed welding parameters of u 1400 r/min and V 63 mm/min. In
CGPed Al and Cu samples at welding parameters of u 1200 r/ bottom of the weld joint, large volume of IMC layers have
min and V 63 mm/min in Al and Cu sides. As can be seen in developed. These layers have hardness values ranging from 126
Fig. 4(f) and Fig. 9(a), the stir zone consists of large Cu particles
and layers. These Cu layers have a high hardness value about
160 HV. This is probably developed due to SPD during FSW
process and producing a high dislocation density; that is why a
high hardness value can be seen in Fig. 12.
The UTS of the FSWed CGPed Al and Cu samples at welding
parameters of u 1200 r/min and V 63 mm/min is 80 MPa.
The weld is fractured from HAZ of Al side. According to
microhardness of this sample, the hardness value of HAZ in Al

Fig. 11 Microstructure of the stir zone of CGPed Al and Cu samples at

u 1200 r/min and V 63 mm/min in: (a) Al side, (b) Cu
side.

Fig. 12 Microhardness proles of CGPed samples subjected to FSW at

Fig. 10 EDS analysis taken from: (a) layer A, (b) layer B in Fig. 9. u 1200 r/min and V 63 mm/min.

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Fig. 13 SEM backscattered electron images (BEI) of the annealed Al and Cu samples FSWed at u 1400 r/min and V 63 mm/min: (a) cross-
sectional macrograph of bottom the joint, (b) magnied view of the rectangular region in (a).

to 195 HV. Ouyang et al.[13] reported that in dissimilar FSW of
Al 6061 to copper, different microhardness levels, from 136 to
760 HV, were produced in weld stir zone corresponding to
various microstructures and material ow patterns. Fig. 14 shows
macrostructure and microstructure of CGPed sample at welding
parameters of u 1400 r/min and V 63 mm/min. No defect
can be found in this weld joint. A great deal of grain renement
can be seen in weld zone in Cu side, in comparison with Cu base
metal. It can be caused by dynamic recrystallization in Cu.
Moreover, Razadeh et al.[28] investigated the effect of post-
annealing on yield strength of two passes CGPed copper sheet.
They reported that the yield strength increases with increasing
annealing temperature due to grain renement resulted from
recrystallization phenomenon. At this stage, increase in grain
boundary density compensates the decrease of dislocation den-
sity and leads to increase of the strength.
Fig. 15 shows microhardness of annealed and CGPed sample
at welding parameters of u 1400 r/min and V 63 mm/min.
Microhardness values of base metal of CGPed samples are
higher than those of base metal of annealed samples; but these

Fig. 14 OM images of dissimilar FSW of CGPed samples at u 1400 r/min and V 63 mm/min: (a) macrostructure of joint, (b)e(e) microstructures
of different regions marked as AeD in (a).

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8 H. Barekatain et al.: J. Mater. Sci. Technol., 2013,
Fig. 15 Microhardness of annealed and CGPed samples FSWed at
u 1400 r/min and V 63 mm/min.
Fig. 16 XRD results of samples at u 1400 r/min and V
80 mm/min: (a) annealed sample, (b) CGPed sample.
values are relatively the same in the stir zones of both cases.
FSW is a thermomechanical process that joins materials, with
imposing SPD at high temperature. It not only can produce
higher hardness in SZ (stir zone) of annealed samples, due to
grain renement and recrystallization phenomena, but also can
reduce the hardness of SZ in SPDed materials due to their un-
stable structure upon heating. Sun et al.[5] and Khorrami et al.[6]
reported this phenomenon in FSW of SPDed aluminum alloys.
The microstructure of annealed and CGPed samples at weld-
ing parameters of u 1400 r/min and V 80 mm/min, can be
seen in Fig. 4(k) and (l), respectively. SZs consist of Cu particles
detached from Cu base metal during FSW. These Cu particles are
surrounded by lots of IMCs layers. Fig. 16 shows XRD results of
annealed and CGPed samples at welding parameters of
u 1400 r/min and V 80 mm/min. Both of the weld joints
contain Al2Cu and Al4Cu9. Fig. 17 shows microhardness prole
Fig. 17 Microhardness of annealed and CGPed samples at welding
parameters of u 1400 r/min and V 80 mm/min.
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Fig. 18 Microstructure of BM of FSW joint of CGPed samples next to
TMAZ at welding parameters of u 1400 r/min and
V 80 mm/min.
of these two weld joints. The hardness value of each individual
zone of weld in CGPed samples is higher than that of annealed
samples. Again, in weld zone of CGPed sample, in Al side,
reduction in hardness value can be seen. According to Fig. 18,
grain boundaries are relatively disappeared. It points out the fact
that grain growth is going on and consequent decrease of hard-
ness value can be seen in CGPed samples. The UTS values of
annealed and CGPed samples are 72 and 81 MPa, respectively.
Place of fracture of these weld joints can be seen in Fig. 3.
According to Table 4, welding parameters of u 1400 r/min
and V 80 mm/min produced welds with higher UTS,
compared with other welding parameters because of lower heat
input that these welding parameters can provide.
4. Conclusions
(1) AA 1050 aluminum alloy and commercially pure copper
has been joined successfully by FSW in annealed and
CGPed conditions.
(2) There is a range of heat input, in which both annealed and
CGPed samples can be joined together successfully.
(3) Several forms of intermetallic compounds are found in weld
zone of FSWed annealed and CGPed samples. These
compounds mainly consist of Al2Cu and Al4Cu9.
(4) Relative reduction in stir zone hardness value of CGPed
sample can be found, while for annealed sample it is
increased compared with their BM due to grain renement.
(5) Regarding tensile test results, generally the weakest part of
weld joints of annealed and CGPed samples are Al base
metal and stir zone, respectively.
Acknowledgments
The authors thank the Research Board of Sharif University
of Technology and Tamkar Industrial Company for the nancial
support and the provision of the research facilities used in this
study.
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Please cite this article in press as: H. Barekatain, et al., Journal of Materials Science & Technology (2013), http://dx.doi.org/10.1016/
j.jmst.2013.11.007