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Interface evolution and mechanical response in dissimilar friction stir welded T-lap joints of aluminum alloy to brass
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DOI：10.1080/01694243.2026.2676727.png)
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Abstract
En 中文
Dissimilar T-lap joints between AA6061 and brass were fabricated using friction stir welding (FSW) under various rotation pitches (ω/v), defined as the ratio of rotational speed (ω) to welding speed (v), ranging from 2.5 to 12.0 rev/mm. The attention is focused on the interfacial evolution and mechanical performance of the joints. Scanning electron microscopy (SEM), energy dispersive spectroscopy, and X-ray diffraction (XRD) were employed to characterize the interface and intermetallic phases. The results show that the rotation pitch strongly influences heat input, material flow, and joint integrity. Increasing rotation pitch enhances elemental diffusion and material mixing, but also promotes hook formation and reduces the effective skin thickness (EST). Interfacial cracking on the aluminum side is identified as the dominant defect under all conditions. This behavior is primarily attributed to the formation of a thick and brittle intermetallic layer, accompanied by strong Cu and Zn diffusion into the aluminum matrix, with Al4Cu9, Al2Cu, Cu4Zn, and CuZn phases identified. These intermetallic compounds (IMCs) result in extremely high hardness (up to ∼850 HV) and premature failure. The highest tensile strength of 250 MPa is achieved at an optimal rotation pitch of 4.5 rev/mm, where fracture occurs in the heat affected zone (HAZ). These findings provide new insight into the relationship between heat input, interfacial stability, and mechanical performance in dissimilar FSWed T-lap joints of aluminum alloy to brass.
Keywords:
Friction stir welding
intermetallic compound
mechanical performance
T-lap joints
interfacial evolution
AA6061
brass
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3.7
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