Evaluation of tensile strength of dissimilar metal pure aluminium and pure copper friction welds

Abstract

Several industrial applications demand the dissimilar metal joints of aluminium and copper, and dissimilar metal welding has been always a challenge. An attempt has been made in the present work in joining pure aluminium and pure copper by continuous drive friction welding. The selected process parameters namely Spindle Speed, Friction Force, Upset Force and Burn-Off are optimized after carrying out the welds by using Taguchi L9 array, followed by ANOVA analysis. As the tensile strength of the joints obtained with optimized parameters is less compared to that of the parent materials, an attempt is made to carry out the dissimilar metal welding by changing the end profile of copper and also by using interlayers. No improvement of tensile strength was observed in welds with different end profiles of copper but there is an improvement in the tensile strength in welds with interlayers.