Upset resistance dissimilar welding of aluminium and copper narrow rods was performed. Effect of the interface characteristics was studied on the joint mechanical and electrical properties. Upset resistance welding (URW) was successful for production of joints with high strength and electrical conductivity between aluminium and copper rods. Reaction layer at the joint interface was composed of the Al2Cu cellular phase and lamellar eutectic structure of α-Al and Al2Cu. Enhancement of the welding current and decrease in the upset force increased the reaction layer thickness and strength of the joint. URW had no significant detrimental effect on the electrical conductivity of the weld zone. Neither the joint strength nor the joint electrical conductivity was improved by in situ post weld heat treatment.
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