Abstract: Friction stir welding was employed to join 2 mm thick 6061 aluminum alloy and T2 copper sheets at rotation speeds ranging from 1 600 r/min to 2 000 r/min under both air and underwater conditions. Then the effects of these two welding environments on the microstructure and mechanical properties of the welds were investigated. The results showed that underwater welding significantly reduced surface flash and almost eliminated tool sticking, leading to a more complex copper-aluminum interface. At rotation speeds of 1 600 r/min and 1 800 r/min, the weld exhibited a unique bowl-shaped morphology, with an increase in copper particle size and a significant reduction in the thickness of the intermetallic compounds layer, as well as a marked increase in hardness in the weld nugget area. At a rotation speed of 2 000 r/min, the maximum tensile strength of the joint reached 135 MPa, approximately 1.7 times that of air welding at the same speed. Compared to air welding, underwater wel-ding significantly enhance the mechanical interlocking at the interface, effectively suppress the formation of intermetallic compounds, although it can not alter the types of intermetallic compounds produced, thereby improving the microstructure and mechanical properties of the welded joint.
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2025, Vol. 39 
