Transition layer material for copper-aluminum dissimilar material connection and preparation method thereof

By setting a copper-zinc alloy and zinc-aluminum alloy transition layer with a specific ratio between dissimilar copper and aluminum materials, the problems of brittle phase formation and low joint strength in aluminum-copper welding are solved, realizing a high-strength, low-stress welded joint suitable for industrial applications such as automotive and aerospace.

CN122099658BActive Publication Date: 2026-07-03SUZHOU UNIV
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Patent Information

Authority / Receiving Office
CN · China
Patent Type
Patents(China)
Current Assignee / Owner
SUZHOU UNIV
Filing Date
2026-04-27
Publication Date
2026-07-03

AI Technical Summary

Technical Problem

When aluminum and copper are directly welded, the differences in their physical and chemical properties can lead to defects such as uneven melting and cracks, and the formation of brittle intermetallic compounds, which affect the stability and strength of the welded joint.

Method used

Using copper-zinc alloy and zinc-aluminum alloy in specific ratios as transition layer materials, copper-aluminum dissimilar materials are connected by laser welding and other methods to form a stable metallurgical bond, suppress the formation of brittle phases, and improve the overall performance of the welded joint.

Benefits of technology

It achieves an effective metallurgical transition between copper and aluminum dissimilar materials, reduces welding temperature, decreases thermal stress, and improves the strength and reliability of welded joints, making it suitable for applications requiring lightweight and high strength.

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Abstract

This invention relates to a transition layer material for joining dissimilar copper and aluminum materials and its preparation method, belonging to the field of welding technology. The transition layer material for joining dissimilar copper and aluminum materials of this invention comprises a copper-zinc alloy and a zinc-aluminum alloy; the mass ratio of the copper-zinc alloy to the zinc-aluminum alloy is (2.8-3.2):(1.8-2.2); the copper-zinc alloy is adjacent to the copper base material, and the zinc-aluminum alloy is adjacent to the aluminum base material; the zinc content in the copper-zinc alloy is 15%-36%, and the aluminum content in the zinc-aluminum alloy is 6%-10%. By setting a specific ratio of copper-zinc alloy and zinc-aluminum alloy between the dissimilar copper and aluminum materials, an effective metallurgical transition between the two materials is achieved, solving the technical problem of the formation of brittle Al-Cu intermetallic compounds due to the large difference in thermal properties between copper and aluminum dissimilar materials, significantly improving the comprehensive performance of copper-aluminum welded joints, and meeting the application requirements of high-end equipment welding manufacturing.
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