Friction welding connector and its method of production

A method for making an electrical connection by joining a first contact part to a second contact part in a material-to-material contact, the method comprising the steps of:

• providing the first contact part comprising a male first joining section arranged towards the second contact part and being a solid, substantially cylindrical post defining the first joining section;
• providing the second contact part comprising a female second joining section arranged towards the first contact part and comprising a hollow profile, the female second joining section comprising an interior surface;
• inserting the first joining section into the second joining section, inserting a rotating friction welding tool through an opening at a distal end of the female second joining section, opposite the end at which the male first joining section is inserted, and bringing the tool into contact with an interior surface of the female second joining section while the male first joining section remains fitted in the female second joining section, thereby forming an internal annular weld interface between the solid male first joining section and the surrounding female second joining section;
• moving the friction welding tool relative to at least one of the first contact part and the second contact part so as to generate welding energy for at least partially plasticizing at least one of a part of the first joining section and the second joining section facing an other contact part;
• wherein a material of the first contact part has a lower mechanical strength or lower yield point than a material of the second contact part;
• wherein the first contact part comprises aluminum or aluminum alloy, and the second contact part comprises copper, copper alloy, brass, or stainless steel;
• and
• wherein the friction welding generates sufficient heat and relative mechanical displacement at said internal annular interface to disrupt aluminum oxide on the first joining section and to prevent reformation during bonding to the copper-containing second joining section.