Experimental Investigation and Analysis of Friction Stir Welding on Dissimilar Materials (Cu and Al-6063)
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Abstract
Friction Stir Welding (FSW) is an automated process that belongs to the category of solid-state welding processes. In this study, FSW was performed on copper to aluminium materials using three different tool designs. In this experiment, proper selection of input rubbing welding parameters is necessary in order to control weld distortion and subsequently increase the efficiency of the process. In order to achieve a high-quality weld and manage weld distortion, it is essential to regulate the input welding parameters. In this study, tests need to be conducted on AA6063 and copper alloy of 6mm thickness using the friction welding method with different shaped tools. The studies compared different tools with various samples of dimensions 100×100×6mm, using the same set of process parameters, including rpm, feed and axial force. With multiple profiles analysed using consistent parameters, a very smooth finish was achieved on cylindrical and threaded tool profiles. Rough bead texture and slight porosity could be seen on the triangular tool edge. The highest tensile strength reached 28.85N/mm2 with a cylindrical 6mm tool profile pin. During this investigation, copper and AA6063 were used with various profiles and it was finally concluded that the cylindrical profile obtained comparatively good weld strength.
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