An experimental study of friction stir welding parameters effect on joint properties of aluminium alloy and copper plate

Abstract

Joining dissimilar metals like copper and aluminium is a complex area of research for the manufacturing industry. To effectively join the AA7075 with copper plates, an experimental investigation on friction stir welding was carried out. A straight cylindrical pin profile tool of H13 tool steel was chosen for this study. On the advancing direction, the AA7075 plates were fixed under the condition of zero tool offset. The tool was positioned at a 2° tilt angle for the entire experiment. Tensile test, microhardness test, SEM and EDS analysis were completed to investigate the effectiveness of the process parameters (tool traverse and rotational speed) in combination with a modified set-up on the microstructure, tensile strength and microhardness of the joint. Fractography was conducted on fractured specimens to identify the mode of failure. Complex microstructures of swirl and vortex-type material flow patterns were created in the stir zone. As a result of SEM analysis, one of the samples (S5) had finer grains at intermediate heat input, which produced excellent microhardness and tensile strength. Fractography identified ductile failure as the predominant mode of failure in the joints. The results of this study include an ultimate tensile strength value of 221.091 MPa with a joint efficiency of 95.05%, yield strength of 159.035 MPa, maximum elongation of 9.335% and a microhardness value of 271 HV for specimen welded at a traverse speed of 60 mm min−1 and a rotational speed of 1400 rpm.