Ni-based filler metal and Ni-Cu-based filler metal were used to obtain copper/stainless steel (Cu/SS) joints through wire-feeding laser welding. Along the SS/weld interface, there exist different grain sizes (from coarse columnar grains to fine equiaxed grains). The heat affected zone (HAZ) on the copper side consisted of two areas with different grain sizes and the size of the grain in the Cu-HAZ of the Ni-Cu-based filled joint was much smaller than that of the Ni-based filled joint. Our results showed that grain refinement at the copper/weld (Cu/weld) interface of the Ni-Cu-based filled joint was observed through high-resolution electron backscattered diffraction (EBSD). There was a hardness elevation at the Cu/weld interface of the Ni-Cu-based filled joint due to the grain refinement on the weld of the copper side. The maximum tensile strength of the Ni-Cu-based filled joint was obtained and reached 91.2% of the tensile strength of the copper base metal (Cu-BM). Joints in this study were observed to fracture in a ductile mode. Furthermore, the Ni-Cu-based filled joint exhibited a higher plastic deformation, which was primarily caused by the large deformation of the weld zone and the large deformation of the Cu-BM due to the high plasticity of the weld, which alleviated the stress concentration, as indicated by 2D-digital image correlation (DIC) test results.

In phased array ultrasonic sector scanning testing, echoes from defects near the detection surface are often overlapped with interface echoes and cannot be characterized. Based on linear acoustic theory, a mathematical model combining the background subtraction and the sum of squares differences algorithm is established to extract the characteristics of near-detection-surface defect echoes. The upper surface of the artificial notch defect is used as a near-detection-surface defect for detection. Specially, linear interpolation algorithm is used to suppress the effect of residual interface echo on the defect echo feature extraction and the effect of different interpolation factors is analyzed. The defect location and size were calculated based on the extracted defect characteristics. The simulation and experimental results indicate that the model can effectively extract the near-detection-surface defect echoes characteristics. Furthermore, when the interpolated signal reaches at least 500 MHz, residual interface echoes can be effectively suppressed. More importantly, according to the extracted defect echo characteristics, the localization and quantitative accuracies of near-surface defects can reach 0.2 mm and 0.3 mm, respectively. These findings provide an effective strategy for phased array ultrasonic sector scanning testing of near-detection-surface defects.