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The aim of this investigation was to study morphological, mechanical and microstructural properties of similar and dissimilar friction stir welds in 1 mm thick sheets of phosphorous-­deoxidised copper and 5083-H111 aluminium alloy. At the welding conditions tested, the aluminium to copper dissimilar welds displayed a mechanical behaviour strongly lower than that presented by the similar welds. The formation of hard and brittle intermetallic phases, such as CuAl₂ and Cu₉Al₄, and/or the severe thickness undermatch registered in the stirred zone of the dissimilar Al/Cu welds were crucial for the drastic reduction in the strength of the joints.

8th International Symposium, 18-20 May 2010, Poster Session, Paper 02