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<p>The impact of utilizing a Magnesium (Mg) interlayer for dissimilar&#xa0;butt joints&#xa0;between AA7075 and pure copper, using Friction Stir Welding (FSW) was examined in this study. Scanning electron backscatter diffraction (EBSD) analysis was deployed to analyze the microstructure of the samples. The&#xa0;corrosion behavior was also analyzed using potentiodynamic polarization tests. Subsequently, a 3-point bend flexural test was done. The results advance understanding of fundamental processes governing intermetallic formation and mechanical behavior in Al-Cu joints. The corrosion study revealed that the corrosion current density (i<sub>corr</sub>) in the AA7075/Mg/Cu sample with the Mg interlayer decreased by approximately 40% compared to that without the Mg interlayer. The FSWed sample with Mg interlayer significantly enhances joint quality by improving mechanical strength and corrosion resistance. Specimens with the interlayer exhibited superior flexural stress (47.71&#xa0;MPa) and sustained higher loads (308.02 N) compared to those without (32.81&#xa0;MPa and 103.06 N). As a result, the inherent issue of intergranular corrosion in the Al-Cu alloy was effectively mitigated at the joint interface. This improvement significantly enhanced the material properties of the Al–Cu bimetals produced via FSW, making them more suitable for demanding applications in the electronics, automotive, and aerospace industries.</p> Graphical Abstract <p></p>

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Studies on Impact of Magnesium (Mg) Interlayers on Dissimilar Friction Stir Welding of Aluminum and Copper

  • 期刊论文

  • 发表日期：

    2025年4月17日

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  • Amos Thounaojam,
  • Abhijith Sahadevan,
  • M. S. Krishnalal,
  • Pranjal Shome,
  • Jyoti Bhukhan Das,
  • Sunilkumar Dhasan

摘要

The impact of utilizing a Magnesium (Mg) interlayer for dissimilar butt joints between AA7075 and pure copper, using Friction Stir Welding (FSW) was examined in this study. Scanning electron backscatter diffraction (EBSD) analysis was deployed to analyze the microstructure of the samples. The corrosion behavior was also analyzed using potentiodynamic polarization tests. Subsequently, a 3-point bend flexural test was done. The results advance understanding of fundamental processes governing intermetallic formation and mechanical behavior in Al-Cu joints. The corrosion study revealed that the corrosion current density (icorr) in the AA7075/Mg/Cu sample with the Mg interlayer decreased by approximately 40% compared to that without the Mg interlayer. The FSWed sample with Mg interlayer significantly enhances joint quality by improving mechanical strength and corrosion resistance. Specimens with the interlayer exhibited superior flexural stress (47.71 MPa) and sustained higher loads (308.02 N) compared to those without (32.81 MPa and 103.06 N). As a result, the inherent issue of intergranular corrosion in the Al-Cu alloy was effectively mitigated at the joint interface. This improvement significantly enhanced the material properties of the Al–Cu bimetals produced via FSW, making them more suitable for demanding applications in the electronics, automotive, and aerospace industries.

Graphical Abstract