Abstract
Friction stir spot welding (FSSW) was conducted to weld a sheet of an aluminum alloy (AA5754-H114) to a commercial sheet of pure copper (Cu) having (2 mm) thickness. It was performed at various tool rotating speeds (800, 1000, and 1250 rpm), times of plunging (30, 60, and 90 sec) using a tool pin geometry or profile (straight cylindrical, threaded cylindrical with the flute, and tapered cylindrical). The welding process parameters were optimized based on the Taguchi method relying upon the design of experiment (DOE). The used sheet is made of “aluminum alloy” overlapped upon copper sheets. The results manifested that the “maximum” shear forces were found at the best or optimum parameters of welding: (1000 rpm) rotational speed and (90 sec) plunging time when using the straight cylindrical pin profile. The Pareto chart of standardize influences of the tensile-shear outcomes elucidated that the time of plunging was the higher influential parameter than the other welding parameters, such as the speed of rotation and the profile of the pin.
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