{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,8]],"date-time":"2026-09-08T05:54:31Z","timestamp":1788846871656,"version":"build-2803163510"},"reference-count":29,"publisher":"MDPI AG","issue":"23","license":[{"start":{"date-parts":[[2024,11,22]],"date-time":"2024-11-22T00:00:00Z","timestamp":1732233600000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"National Natural Science Foundation of China Youth Fund","award":["51704092"],"award-info":[{"award-number":["51704092"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>Dissimilar welding between aluminum and copper poses significant challenges, primarily due to differences in their thermal and mechanical properties, resulting in brittle intermetallic compounds, limited joint strength, and high electrical resistivity. This study aims to overcome these issues by employing Ag-18Cu-10Zn filler material and optimizing laser power with a focus on improving joint strength and electrical conductivity. The results indicate that the incorporation of silver and zinc enhances the phase composition and microstructure of the weld. By forming solid solution phases such as Ag2Al and Cu5Zn8, the brittle Al2Cu phase commonly found in traditional Al\/Cu welding is replaced. This not only promotes the heterogeneous nucleation of fine silver-rich grains but also restricts the excessive growth of silver-poor grains, resulting in a uniform distribution of fine grains throughout the weld. These modifications contribute to both fine-grain strengthening and dispersion strengthening. At an optimal laser power of 750 W, joint strength reaches 109 MPa, while joint resistivity decreases to 3.19 \u03bc\u03a9\u00b7cm, 12.6% lower than that of the aluminum alloy base material. This study proposes a process for achieving highly conductive, reliable Al\/Cu dissimilar metal joints, potentially impacting the aluminum\u2013copper connections in battery modules for new energy vehicles.<\/jats:p>","DOI":"10.3390\/ma17235726","type":"journal-article","created":{"date-parts":[[2024,11,22]],"date-time":"2024-11-22T10:17:23Z","timestamp":1732270643000},"page":"5726","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":6,"title":["Influence of Ag-18Cu-10Zn Filler Material on Microstructure and Properties of Laser-Welded Al\/Cu Dissimilar Butt Joints"],"prefix":"10.3390","volume":"17","author":[{"given":"Ziquan","family":"He","sequence":"first","affiliation":[{"name":"School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Fei","family":"Liu","sequence":"additional","affiliation":[{"name":"School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Ping","family":"Gao","sequence":"additional","affiliation":[{"name":"School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Lihui","family":"Pang","sequence":"additional","affiliation":[{"name":"School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Yong","family":"Su","sequence":"additional","affiliation":[{"name":"School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2024,11,22]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","unstructured":"Li, J., Zillner, J., and Balle, F. (2023). In-depth evaluation of ultrasonically welded Al\/Cu joint: Plastic deformation, microstructural evolution, and correlation with mechanical properties. Materials, 16.","DOI":"10.3390\/ma16083033"},{"key":"ref_2","doi-asserted-by":"crossref","unstructured":"Kaufmann, F., Strugulea, M., H\u00f6ltgen, C., Roth, S., and Schmidt, M. (2023). Seam properties of overlap welding strategies from copper to aluminum using green laser radiation for battery tab connections in electric vehicles. Materials, 16.","DOI":"10.3390\/ma16031069"},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Shin, W.-S., Cho, D.-W., Jung, D., Kang, H., Kim, J.O., Kim, Y.-J., and Park, C. (2021). Investigation on laser welding of Al ribbon to Cu sheet: Weldability, microstructure, and mechanical and electrical properties. Metals, 11.","DOI":"10.3390\/met11050831"},{"key":"ref_4","doi-asserted-by":"crossref","unstructured":"Beygi, R., Carbas, R., Marques, E., Barbosa, A., Kasaei, M., and da Silva, L. (2024). Mechanism of toughness enhancement of brittle fracture by intermittent \u03b7-intermetallic in Al\/Cu joint made by FSW. Mater. Sci. Eng. A, 890.","DOI":"10.1016\/j.msea.2023.145907"},{"key":"ref_5","doi-asserted-by":"crossref","unstructured":"Yan, S., Li, Z., Song, L., Zhang, Y., and Wei, S. (2023). Research and development status of laser micro-welding of aluminum-copper dissimilar metals: A review. Opt. Lasers Eng., 161.","DOI":"10.1016\/j.optlaseng.2022.107312"},{"key":"ref_6","doi-asserted-by":"crossref","unstructured":"Dai, W., Guo, W., Li, Q., Xiao, J., Li, W., and Zhang, H. (2024). Homogenization of local microstructure and mechanical properties in friction stir welded Al-Cu alloy joint achieved through laser shock peening. J. Mater. Process. Technol., 333.","DOI":"10.1016\/j.jmatprotec.2024.118579"},{"key":"ref_7","doi-asserted-by":"crossref","unstructured":"Mila\u0161inovi\u0107, V., Alil, A., Mila\u0161inovi\u0107, M., Vencl, A., Hatala, M., Diki\u0107, S., and Gligorijevi\u0107, B. (2024). Continuous drive friction welded Al\/Cu joints produced using short welding time, elevated rotational speed, and high welding pressures. Materials, 17.","DOI":"10.3390\/ma17133284"},{"key":"ref_8","doi-asserted-by":"crossref","unstructured":"Ma, B., Gao, X., Huang, Y., Zhang, Y., and Huang, Y. (2024). Effect of different pulse shapes on the laser welding of aluminum and copper. Opt. Laser Technol., 171.","DOI":"10.1016\/j.optlastec.2023.110312"},{"key":"ref_9","doi-asserted-by":"crossref","unstructured":"Li, G., Song, J., Lu, X., Zhu, X., Xu, S., and Guo, Y. (2020). Investigation on microstructure and mechanical properties of Al\/Cu butt joints by CMT method in asymmetrical V-groove configuration. Metall. Res. Technol., 117.","DOI":"10.1051\/metal\/2020028"},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"1945","DOI":"10.1016\/j.jmrt.2021.07.058","article-title":"Microstructure, mechanical and electrical properties of dissimilar friction stir welded 2024 aluminum alloy and copper joints","volume":"14","author":"Khajeh","year":"2021","journal-title":"J. Mater. Res. Technol."},{"key":"ref_11","doi-asserted-by":"crossref","unstructured":"Chang, Z., Huang, M., Wang, X., Wang, H., Sun, G., and Zhou, L. (2023). Microstructure Evolution and Mechanical Properties of Thick 2219 Aluminum Alloy Welded Joints by Electron-Beam Welding. Materials, 16.","DOI":"10.3390\/ma16217028"},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"78","DOI":"10.1016\/j.jmapro.2021.08.025","article-title":"In-depth evaluation of laser-welded similar and dissimilar material tab-to-busbar electrical interconnects for electric vehicle battery pack","volume":"70","author":"Kumar","year":"2021","journal-title":"J. Manuf. Process."},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"26332","DOI":"10.1021\/acsomega.3c02838","article-title":"Impact of bonding temperature on microstructure, mechanical, and fracture behaviors of TLP bonded joints of Al2219 with a Cu interlayer","volume":"8","author":"Vatnalmath","year":"2023","journal-title":"ACS Omega"},{"key":"ref_14","doi-asserted-by":"crossref","unstructured":"Sas-Boca, I.-M., Ilu\u021biu-Varvara, D.-A., Tintelecan, M., Aciu, C., Frunz\u04d1, D.I., and Popa, F. (2022). Studies on Hot-Rolling Bonding of the Al-Cu Bimetallic Composite. Materials, 15.","DOI":"10.3390\/ma15248807"},{"key":"ref_15","doi-asserted-by":"crossref","unstructured":"Tayebi, P., Nasirin, A.R., Akbari, H., and Hashemi, R. (2024). Experimental and Numerical Investigation of Forming Limit Diagrams during Single Point Incremental Forming for Al\/Cu Bimetallic Sheets. Metals, 14.","DOI":"10.3390\/met14020214"},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"2236","DOI":"10.1016\/j.jmrt.2024.06.198","article-title":"Microstructure investigation and optimization of process parameters of ultrasonic welding for Al\u2013Cu dissimilar joints using design of experiment","volume":"31","author":"Goodarzi","year":"2024","journal-title":"J. Mater. Res. Technol."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"543","DOI":"10.1007\/s40194-023-01608-1","article-title":"Microstructure and mechanical properties of dissimilar metal joints of copper\/aluminum using FeCoCrNiMn filler material","volume":"68","author":"Liu","year":"2024","journal-title":"Weld. World"},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"343","DOI":"10.1016\/j.jmapro.2020.09.078","article-title":"Influence of Ni interlayer on microstructure and mechanical properties of laser welded joint of Al\/Cu bimetal","volume":"59","author":"Yan","year":"2020","journal-title":"J. Manuf. Process."},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"1419","DOI":"10.1007\/s00170-023-11839-7","article-title":"Microstructural and mechanical characteristics of friction stir welded Al6101\/C11000 joints with zinc and silver interlayer","volume":"128","author":"Payak","year":"2023","journal-title":"Int. J. Adv. Manuf. Technol."},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"226","DOI":"10.1016\/j.jmapro.2021.04.065","article-title":"Interfacial microstructure and reaction mechanism with various weld fillers on laser welding-brazing of Al\/Cu lap joint","volume":"67","author":"Lei","year":"2021","journal-title":"J. Manuf. Process."},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"79","DOI":"10.1007\/s12541-023-00921-5","article-title":"Microstructure and performance study of Al\/Cu Laser welding with Ag interlayer","volume":"25","author":"Chen","year":"2024","journal-title":"Int. J. Precis. Eng. Manuf."},{"key":"ref_22","doi-asserted-by":"crossref","unstructured":"Eslami, N., Hischer, Y., Harms, A., Lauterbach, D., and B\u00f6hm, S. (2019). Influence of copper-sided tin coating on the weldability and formation of friction stir welded aluminum-copper-joints. Metals, 9.","DOI":"10.3390\/met9020179"},{"key":"ref_23","doi-asserted-by":"crossref","unstructured":"Guo, J., Li, C., Bian, J., Zhang, J., and Geng, B. (2023). Microstructures and Electrical Resistivity of Aluminum\u2013Copper Joints. Metals, 13.","DOI":"10.3390\/met13081474"},{"key":"ref_24","doi-asserted-by":"crossref","unstructured":"Huan, P.-C., Tang, X.-X., Sun, Q., Akira, K., Wang, X.-N., Wang, J., Wang, J.-L., Wei, X., and Di, H.-S. (2022). Comparative study of solder wettability on aluminum substrate and microstructure-properties of Cu-based component\/aluminum laser soldering joint. Mater. Des., 215.","DOI":"10.1016\/j.matdes.2022.110485"},{"key":"ref_25","doi-asserted-by":"crossref","first-page":"587","DOI":"10.1007\/s11665-022-07115-6","article-title":"Characteristics of torch-offset cold metal transition-cycle step welding of 5052Al alloy with T2 copper via Al-12Si filler","volume":"32","author":"Xu","year":"2023","journal-title":"J. Mater. Eng. Perform."},{"key":"ref_26","doi-asserted-by":"crossref","first-page":"217","DOI":"10.1016\/j.jallcom.2004.06.078","article-title":"The Ag\u2013Al\u2013Cu system: II. A thermodynamic evaluation of the ternary system","volume":"387","author":"Witusiewicz","year":"2005","journal-title":"J. Alloys Compd."},{"key":"ref_27","unstructured":"(2024). Standard Test Methods for Tension Testing of Metallic Materials (Standard No. ASTM E8\/E8M-24)."},{"key":"ref_28","doi-asserted-by":"crossref","unstructured":"Zhang, Z., Zhang, J., Zhao, X., Cheng, X., Liu, X., and Zhang, Q. (2024). Thermodynamic Simulation Calculations of Phase Transformations in Low-Aluminum Zn-Al-Mg Coatings. Materials, 17.","DOI":"10.3390\/ma17112719"},{"key":"ref_29","doi-asserted-by":"crossref","unstructured":"Sun, T., Jabar, S., Kumar, N., Liu, C., Ceglarek, D., and Franciosa, P. (2024). The impact of ring-shaped laser beam on dissimilar welding of Al-Cu thin sheets for battery tab-to-busbar connection: Microstructural, mechanical and electrical characteristics. Opt. Laser Technol., 179.","DOI":"10.1016\/j.optlastec.2024.111312"}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/17\/23\/5726\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,10]],"date-time":"2025-10-10T16:37:47Z","timestamp":1760114267000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/17\/23\/5726"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2024,11,22]]},"references-count":29,"journal-issue":{"issue":"23","published-online":{"date-parts":[[2024,12]]}},"alternative-id":["ma17235726"],"URL":"https:\/\/doi.org\/10.3390\/ma17235726","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2024,11,22]]}}}