In this paper, dissimilar Al⁻Cu joints of AA1050H/C1100-Cu, AA6061-T6/C1100-Cu, and AA1050H/C2600-brass are successfully welded by a friction stir welding (FSW) process. The aim of the present study is not only to examine the tensile strength, but also to investigate the reliability, durability, and failure behaviors of joints as correlated with the metallurgical bonded microstructures of varied Al⁻Cu joints. Experimental evidence confirms that good welding quality for an FSW Al⁻Cu dissimilar joint is obtained when pure Cu and brass plates are positioned at the advancing side. Cross-sectional microstructures reveal that the AA6061-T6/C1100-Cu joint exhibits an extensive metallurgical bonded region with significant onion rings in the welding zone, whereas the AA1050H/C2600-brass joint generally displays a clear mechanical kissing bonded boundary at the joint interface. Al₂Cu, Al₄Cu₉, and γ-Cu₅Zn₈ are major intermetallic compounds (IMCs) that are formed within the metallurgical bonded welding zone. The Weibull model provides a statistical method for assessing the failure mechanism of FSW Al⁻Cu joints. Better welding reliability and tensile properties with ductile dimpled ruptures are obtained for the Al⁻Cu joints with a typical metallurgical bonded zone. However, a mechanical kissing bonded interface and thick interfacial IMCs result in the deterioration of tensile strength with a brittle fracture and a rapid increase in the failure probability of Al⁻Cu joints.
Keywords: dissimilar joints; engineering reliability; failure strength; friction stir welding; metallurgical bonding microstructure; the Weibull model.