Experimental optimization of the FSW parameters to weld the dissimilar Al- and Cu-alloys by using additives at their joints

Abstract

Friction stir welding (FSW) stands as a promising technique for joining materials, offering advantages over conventional methods. This study investigates the influence of tool tilt angle, rotational speed and profile on welded joint characteristics using a design of experiment (DOE) approach. The research objective aims to determine optimal parameter combinations for improved mechanical properties. Methodology entails the systematic variation of tilt angle, rotational speed and tool profile in a DOE setup, with subsequent FSW of samples. Mechanical testing, including tensile, bend and hardness tests, is conducted on 24 samples, with scanning electron microscope (SEM) and microstructure analysis on two specimens. Results reveal that higher tilt angles, rotational speeds and threaded profiles yield increased tensile strength but decreased ductility. Similarly, bend tests show higher fracture loads but reduced deflection before fracture under these conditions. Hardness tests indicate elevated hardness in welded areas, with variations based on input parameters. Main findings highlight the importance of parameter optimization for desired mechanical properties. Lower tilt angles and rotational speeds promote smoother material flow and uniform heating, resulting in consistent microstructure and hardness distribution. In conclusion, this study provides valuable insights for optimizing FSW parameters to achieve desired mechanical properties in welded joints. The combination of a 2° tilt angle, threaded tool profile and 1500 rpm rotational speed demonstrated the highest tensile strength, while a 1° tilt angle, cylindrical tool profile and 1000 rpm rotational speed yielded highest ductility.