The Experimental Investigation on various additives used in Friction Stir Welded Joints of Aluminium and Copper Alloys

Abstract

This paper presents an experimental investigation into the influence of different input parameters on FSW joints of copper and Aluminium alloys. An experimental investigation has been carried out into the effects of diverse input parameters on Friction Stir Welding of copper and aluminium alloys. The FSW process parameters encompassed the use of both cylindrical and threaded profiles of the welding tool, employing tilt angles of 2 and 3 degrees, tool speeds set at 1000 rpm and 1500 rpm. Twenty-four specimens, consisting of Cu and Al alloys plates were crafted for the experimentation. Employing a vertical milling machine, simple butt joints were fashioned in aluminium and copper alloys. The joints were fortified using a combination of five additives—aluminium oxide, boron carbide, zirconium oxide, zirconium bromide, and silicon carbide—in equal ratios to enhance the FSW joints.

The study tested the joints for a range of mechanical properties such as Tensile testing, Macrostructure, Hardness, as well as Bending testing. A comparative analysis among these joints was made to explain their mechanical performance.

The findings of this experimental investigation provide valuable insights into how variations in input parameters, coupled with the use of specific additives.