Influence of Optimized Process Parameter of Friction STIR Welding On Copper and Aluminium Alloy with Various Filler Materials

Abstract

The fusion of materials through the application of heat, Friction Stir Welding operates on a fundamentally different principle. It is the concept of mechanical stirring through "mixing" the materials together while they are in a plasticized state. The specific focus of our research emerges joining Aluminum alloy and copper dissimilar materials through FSW in the aerospace industry, aluminum alloys are often used for their lightweight properties, while copper's excellent conductivity is essential in electrical systems. The ability to effectively join these materials opens new possibilities for lightweight, high performance components. The primary objective is to achieve the fusion of aluminum alloy and copper without the use of filler materials. This approach allows us to explore the impact of tool geometry on the resulting joint, when applied to dissimilar materials. By introducing filler materials, we seek to enhance the bonding process between the aluminum alloy and copper plates to achieve not only a stronger and more durable joint but also to explore the influence of filler materials on the micro-structural properties of the weld. To assess the joints tests, including Tensile Testing which allows us to determine the tensile strength and ductility of the joints. Tensile Testing is a fundamental measure of a material's ability to withstand axial forces without rupture. By applying this test to our FSW joints, we gain insights into their mechanical properties and structural integrity. Hardness testing as a means of characterizing the material properties of the weld that measure of a material's resistance to deformation provides crucial information about the structural changes induced by the welding process. Macrostructure Testing serves as a macroscopic examination of the welds, offering insights into the overall quality and structural integrity of the joints. This study aspires to make substantial contributions to the optimization of FSW as a viable and efficient method for the bonding of dissimilar materials, specifically aluminum alloys and copper.