Influence of Process Parameters on Joint Characteristics in Friction Stir Welding of Al/Cu Dissimilar Materials for Lithium-ion Battery

Abstract

Abstract The dissimilar lap joining of 1050 Al alloy with thickness of 0.5 mm and commercial pure copper with thickness of 1.0 mm has been carried out by Friction Stir Welding (FSW). The influence of process parameters on Al-Cu dissimilar joint characteristics was investigated. The tensile-shear test results indicated that a higher heat input with increasing rotational speed and decreasing travel speed contributed to a higher tensile-shear load. The maximum tensile-shear load of the Al-Cu dissimilar joint was 913 N when obtained under a rotational speed of 600 rpm and a travel speed of 60 mm/min. According to the Al-Cu joint electrical resistance test, the minimum electrical resistance value was about 70 µΩ, which corresponded with the maximum tensile shear load. It can be inferred that the defect-free welded joint and sufficient joining area contributed to smooth current flow.