A Brief Review on Interfaces of Copper Welded to Different Materials

Year : 2026 | Volume : 16 | Issue : 01 | Page : 25 36
    By

    Samarth,

  • Mohammad Shareek,

  • Satyanarayana,

  • Veerabhadrappa Algur,

  • Kumar Swamy M C,

  1. Final Year Student, Department of Mechanical Engineering, Alvas Institute of Technology and Engineering, Moodbidri 574225, Karnataka, India
  2. Final Year Student, Department of Mechanical Engineering, Alvas Institute of Technology and Engineering, Moodbidri 574225, Karnataka, India
  3. Professor and Head, Department of Mechanical Engineering, Alvas Institute of Technology and Engineering, Moodbidri 574225, Karnataka, India
  4. Associate Professor, Department of Mechanical Engineering, Alvas Institute of Technology and Engineering, Moodbidri 574225, Karnataka, India
  5. Sr. Assistant Professor, Department of Mechanical Engineering, Alvas Institute of Technology and Engineering, Moodbidri 574225, Karnataka, India

Abstract

In engineering applications, three metals with high conductivity are primarily used such as copper (Cu), aluminium (Al), and silver (Ag). Each has its unique set of properties that affect specific engineering applications. Infact the choice of conductor depends on a mixture of cost, technical parameters, and environmental conditions. Among these, Copper is widely valued in engineering applications due to its antimicrobial property, excellent electrical (about 100% IACS) and thermal conductivity, corrosion resistance, ease of connection, and mechanical as well as recyclable properties. However, welding copper alloys to dissimilar metals, such as steel, aluminium, nickel (Ni)-based alloys, and titanium (Ti), poses significant challenges due to differences in physical properties, metallurgical compatibility, and thermal behaviour. This review paper explores the current state of research and technological developments in the welding of copper to copper alloys and other dissimilar metals. It provides a comprehensive overview of various welding techniques, including laser welding, fusion welding, solid-state welding (e.g., friction stir and explosive welding), and advanced hybrid methods. Emphasis is placed on the mechanisms of joint formation, metallurgical interactions at the weld interface, formation of intermetallic compounds, and the impact of process parameters on the quality of joints for copper welded to stainless steel, steel joints, aluminium, titanium, brass, magnesium (Mg), molybdenum (Mo), tin (Sn), nickel alloy, and tantalum (Ta).  The goal of this review is to consolidate existing knowledge, identify key technical challenges, and highlight future directions for research and industrial applications to weld copper for different engineering applications, including characterisation of the interface with different techniques such as metallurgical microscope, scanning electron microscope (SEM), micro-Vickers hardness testing etc.  The literature review suggests that adopting advanced computational modelling techniques such as artificial intelligence, smart manufacturing, and data-driven design to support the creation of a robust Cu joint with other novel materials is highly essential.

Keywords: Copper, Dissimilar metals, Explosive welding, Interface characterisation, Wavy interface

[This article belongs to Trends in Mechanical Engineering & Technology ]

How to cite this article:
Samarth, Mohammad Shareek, Satyanarayana, Veerabhadrappa Algur, Kumar Swamy M C. A Brief Review on Interfaces of Copper Welded to Different Materials. Trends in Mechanical Engineering & Technology. 2026; 16(01):25-36.
How to cite this URL:
Samarth, Mohammad Shareek, Satyanarayana, Veerabhadrappa Algur, Kumar Swamy M C. A Brief Review on Interfaces of Copper Welded to Different Materials. Trends in Mechanical Engineering & Technology. 2026; 16(01):25-36. Available from: https://journals.stmjournals.com/tmet/article=2026/view=236223


References

  1. Davis, J. R. (Ed.). (2001). Copper and Copper Alloys. ASM International.
  2. Torkamany, M. J., et al. (2008). Laser welding of copper to stainless steel using pulsed Nd:YAG laser. Journal of Materials Processing Technology, 202(1–3), 250–255.
  3. Kalms, S., et al. (2016). Friction stir welding of copper and steel: Microstructure and mechanical properties. Materials Science and Engineering A, 676, 1–9.
  4. Zhang, H., et al. (2020). Dissimilar laser welding of copper and aluminum alloys: Recent progress and future perspectives. Journal of Manufacturing Processes, 56, 693–709.
  5. Chen, Y., et al. (2019). Influence of interlayers on diffusion bonding of copper and Materials and Design, 183, 108162.
  6. Sapanathan, T., et al. (2022). Application of Cu in adaptive control for dissimilar metal welding. Welding Journal, 101(5), 150–158.
  7. Ma, Z. Y., & Mishra, R. S. (2005). Friction stir welding and processing. Materials Science and Engineering R, 50(1–2), 1–78.
  1. Ma, Z. Y. (2011). Effect of friction stir welding parameters on the microstructure and mechanical properties of the dissimilar Al–Cu joints. Materials Science and Engineering A, 528(13–14), 4683–4689.

https://doi.org/10.1016/j.msea.2011.02.072

  1. Mubiayi, M. P., & Akinlabi, E. T. (2015). Friction stir welding of dissimilar metals between aluminum alloys and copper – Alloys Proceedings of the World Congress on Engineering, 2, 1–5.
  1. Steen, W.M. Laser Material Processing; Springer: London, UK, 2003; Volume 113, ISBN 9781849960618. [Google Scholar]
  2. Chatterjee, S.; Sankar, S.; Bharadwaj, V.; Upadhyay, B.N.; Bindra, K.S.; Thomas, J. Parametric appraisal of mechanical and metallurgical behavior of butt welded joints using pulsed Nd:YAG laser on thin sheets of AISI 316. Opt. Laser Technol. 2019, 117, 186–199. [Google Scholar] [CrossRef]
  3. Kumar, N.; Mukherjee, M.; Bandyopadhyay, A. Study on laser welding of austenitic stainless steel by varying incident angle of pulsed laser beam. Opt. Laser Technol. 2017, 94, 296–309. [Google Scholar] [CrossRef]
  4. Dai, J.; Yu, B.; Ruan, Q.; Chu, P.K. Improvement of the laser-welded lap joint of dissimilar mg alloy and cu by incorporation of a Zn interlayer. Materials 2020, 13, 2053. [Google Scholar] [CrossRef]
  5. Chai, D.; Wu, D.; Ma, G.; Zhou, S.; Jin, Z.; Wu, D. The effects of pulse parameters on weld geometry and microstructure of a pulsed laser welding Ni-base alloy thin sheet with filler wire. Metals 2016, 6, 237. [Google Scholar] [CrossRef] [Green Version]
  6. Lerra, F.; Ascari, A.; Fortunato, A. The influence of laser pulse shape and separation distance on dissimilar welding of Al and Cu films. J. Manuf. Process. 2019, 45, 331–339. [Google Scholar] [CrossRef]
  7. Kumar, P.; Nath, S. Comparative analysis of pulsed Nd:YAG laser welding of 304L and 904L stainless steel. Mater. Today Proc. 2020, 33, 5019–5023. [Google Scholar] [CrossRef]
  8. Chang, W.S.; Na, S.J. A study on the prediction of the laser weld shape with varying heat source equations and the thermal distortion of a small structure in micro-joining. J. Mater. Process. Technol. 2002, 120, 208–214. [Google Scholar] [CrossRef]
  9. Abioye, T.E.; Zuhailawati, H.; Aizad, S.; Anasyida, A.S. Geometrical, microstructural and mechanical characterization of pulse laser welded thin sheet 5052-H32 aluminium alloy for aerospace applications. Trans. Nonferr. Met. Soc. China 2019, 29, 667–679. [Google Scholar] [CrossRef]
  10. Sánchez-Amaya, J.M.; Delgado, T.; González-Rovira, L.; Botana, F.J. Laser welding of aluminium alloys 5083 and 6082 under conduction regime. Appl. Surf. Sci. 2009, 255, 9512–9521. [Google Scholar] [CrossRef]
  11. Sun, Q.; Di, H.; Li, J.; Wang, X. Effect of pulse frequency on microstructure and properties of welded joints for dual phase steel by pulsed laser welding. JMADE 2016, 105, 201–211. [Google Scholar] [CrossRef]
  12. Landowski, M.; Świerczyńska, A.; Rogalski, G.; Fydrych, D. Autogenous fiber laser welding of 316L austenitic and 2304 lean duplex stainless steels. Materials 2020, 13, 2930. [Google Scholar] [CrossRef] [PubMed]
  13. Loureiro, A., et al. “Effect of explosive mixture on quality of explosive welds of copper to aluminium.” Materials & Design95 (2016): 256-267.
  14. Aydın, Kemal, Yakup Kaya, and Nizamettin Kahraman. “Experimental study of diffusion welding/bonding of titanium to copper.” Materials & Design37 (2012): 356-368.
  15. Paul, H., et al. “Towards a better understanding of the phase transformations in explosively welded copper to titanium sheets.” Materials Science and Engineering: A784 (2020): 139285.
  16. Cao, R., Z. Feng, and J. H. Chen. “Microstructures and properties of titanium–copper lap welded joints by cold metal transfer technology.” Materials & Design53 (2014): 192-201.
  1. Cao, R., et al. “Study on cold metal transfer welding–brazing of titanium to copper.” Materials & Design (1980-2015)56 (2014): 165-173.
  2. Erdem, Mehmet. “Investigation of structure and mechanical properties of copper-brass plates joined by friction stir welding.” The International Journal of Advanced Manufacturing Technology9 (2015): 1583-1592.
  3. Gharavi, Farhad, et al. “Effect of welding heat input on the microstructure and mechanical properties of dissimilar friction stir-welded copper/brass lap joint.” Materials Research22 (2019): e20180506.
  4. Chen, Yuhua, Jilin Xie, and Wenming Cao. “Research on friction stir welded joints of Copper to Magnesium alloy.” International Symposium on Mechanical Engineering and Material Science (ismems-16). Atlantis Press, 2016
  1. Zhou, Xian-Rong, et al. “Microstructures and properties of the dissimilar joint of pure molybdenum/T2 copper by single-mode laser welding.” International Journal of Refractory Metals and Hard Materials101 (2021): 105667.
  2. Satyanarayan, Tanaka, Shigeru, Akihisa Mori, and Kazuyuki Hokamoto. “Welding of Sn and Cu plates using controlled underwater shock wave.” Journal of Materials Processing Technology245 (2017): 300-308.
  3. Satyanarayan, Akihisa Mori, Masatoshi Nishi, Kazuyuki Hokamoto, “Underwater shock wave weldability window for Sn-Cu plates”, Journal of Materials Processing Tech. 267 (2019) 152–158
  4. . Mali, V. I., et al. “Microstructure and mechanical properties of Ti/Ta/Cu/Ni alloy laminate composite materials produced by explosive welding.” The International Journal of Advanced Manufacturing Technology9 (2017): 4285-4294.

34.Greenberg, B. A., et al. “The problem of intermixing of metals possessing no mutual solubility upon explosion welding (Cu–Ta, Fe–Ag, Al–Ta).” Materials characterization 75 (2013): 51-62.

Regular Issue Subscription Review Article
Volume 16
Issue 01
Received 30/12/2025
Accepted 16/01/2026
Published 30/01/2026
Publication Time 31 Days
16

Login


My IP

PlumX Metrics