Microstructure and mechanical performance of FSWed joint of T2 copper and AA 1061

Welding of copper and aluminium has been problematic with tradition fusion method. The friction stir welding (FSW) was employed to butt weld the T2 copper and 1061 aluminium alloy plates. The welding parameters were planned by the orthogonal experiment design method. The samples obtained in experiments were investigated in the aspects of microstructure, tensile strength, fatigue performance and micro-hardness. Sound weld with the best tensile strength and fatigue life was produced under the welding parameters of rotation speed, 1100 rpm and welding speed 50 mm min −1 . The tensile strength was 193.16 MPa, 85% of the base aluminium material. Three intermetallic compounds of CuAl, Cu 3 Al and Cu 9 Al 4 were detected at the copper-aluminium interface in X-ray diffraction analysis.