Authors: Miss Gaikwad Janhvi Anurath, Miss. Kadam Vaishnavi Raju, Mr. Chinmay Shinde, Mr. Narayanpure Sujal, Prof. Dr.Ashish Kumar
Abstract: Friction Stir Welding (FSW) is an advanced solid-state joining technique used for welding similar and dissimilar metals without melting the base materials. In this project, an experimental investigation has been carried out to study the mechanical properties of dissimilar joints between Aluminium Alloy AA6061 and Copper (ETP Copper) using the Friction Stir Welding process. The purpose of this study is to evaluate the effect of welding parameters on the strength and quality of the welded joints. The welding experiments were performed using a carbide conical ball nose tool under different process conditions such as rotational speed, welding speed, and plunge depth. Proper fixture arrangements and clamping systems were used to obtain defect-free joints. AA6061 aluminium and copper were selected due to their wide applications in aerospace, automobile, marine, electrical, and heat transfer industries where light weight materials with high thermal and electrical conductivity are required. After the welding process, the joints were examined through visual inspection and tested for various mechanical properties including tensile strength, hardness, and microstructural characteristics. The experimental results showed that welding parameters greatly affect heat generation, material flow, and intermetallic compound formation at the weld interface. Optimized welding conditions produced sound joints with better tensile strength and uniform hardness distribution. The investigation concludes that Friction Stir Welding is an efficient and economical process for joining dissimilar aluminium-copper materials with fewer defects and Improved mechanical properties compared to conventional fusion welding methods. The results of this project can be useful for industrial applications requiring strong, lightweight, and conductive dissimilar metal joints.
DOI: http://doi.org/
