Achieving High-Quality Aluminum to Copper Dissimilar Metals Joint via Friction Stir Double-Riveting Welding

In order to achieve a high-quality joining of aluminum (Al) and copper (Cu) dissimilar metals, new friction stir double-riveting welding (FSDRW) with Cu rod as the rivet was proposed, rotating tool large concave angle shoulder specially designed. The results showed that under thermal–mechanical effect tool, deformed be double riveting heads structure anchor at upper surface Al plate an above lap interface joint, these two anchors greatly enhanced mechanical interlocking Al/Cu joint. effective bonding interfaces were formed among structure, lower plate, which contained Cu/Cu interface. without kissing bond rationally thin AlCu Al2Cu intermetallic compounds (IMCs) layers beneficial heightening joint tensile shear strength. maximum load FSDRW achieved 5.52 kN, different plunging depths presented mixed mode ductile fracture brittle fracture. This novel technique owns advantages strong superb metallurgical bonding, provides approach acquiring metals