The overlap joint

consisting of 6061 aluminum alloy which is 0.5mm thickness and T2 copper which is 2mm thickness

was welded in the micro friction stir welding process with zero tile angle. Meanwhile

the characterizations of welding process were studied by analyzing the materials selection of welding tool

weld quality and mechanical properties. Result showed that comparing to hot work die steel

welding tool made of high-speed tool steel had a longer working life. As for the overlap joint of aluminum and copper

an excellent weld shape can be acquired through micro friction stir welding with zero tile angle

moreover

the process window was wide

the mechanical properties of the joint are excellent

and its load bearing capacity can be over 95% of that of the 6061 aluminum alloy. However when the welding speed was 200mm/min and the spindle speed over 25000r/min

the grooves defect appeared on the weld.