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<p>Dissimilar welding of aluminium and copper is challenging due to their contrasting thermal and mechanical properties. Friction Stir Welding (FSW) offers a viable solution, but high heat input often leads to brittle intermetallic compound formation. This study investigates Underwater Friction Stir Welding (UFSW) to mitigate such effects in Al–Cu joints. A Taguchi L9 orthogonal array was employed with pin diameter, rotational speed, and welding speed as variables. The results showed that ultimate tensile strength (UTS) varied between 164.2 and 251.1&#xa0;MPa, yield strength (YS) ranged from 123.2 to 167.7&#xa0;MPa, and elongation spanned 7.0–12.1% across the experimental matrix. The highest UTS and YS were recorded at a pin diameter of 8&#xa0;mm, 900&#xa0;rpm, and 50&#xa0;mm/min welding speed, while moderate parameters provided more balanced elongation. ANOVA confirmed rotational speed and pin diameter as the most influential factors, whereas welding speed exhibited an inverse effect on strength. Microstructural analyses using EDS and EBSD further highlighted improved material flow in weld nugget with intermixing of materials. This reduces intermetallic formation and refinement underscoring UFSW’s potential to enhance Al–Cu joint performance.</p>

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Effect of Process Parameters on the Joint Properties of 6061 Al Alloy-Pure Copper Joints Produced in Under Water FSW

  • 期刊论文

  • 发表日期：

    2025年11月11日

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  • Gunjan Yadav,
  • Ratnesh Kumar Raj Singh,
  • Shahanwaz Alam,
  • Archana Singh

摘要

Dissimilar welding of aluminium and copper is challenging due to their contrasting thermal and mechanical properties. Friction Stir Welding (FSW) offers a viable solution, but high heat input often leads to brittle intermetallic compound formation. This study investigates Underwater Friction Stir Welding (UFSW) to mitigate such effects in Al–Cu joints. A Taguchi L9 orthogonal array was employed with pin diameter, rotational speed, and welding speed as variables. The results showed that ultimate tensile strength (UTS) varied between 164.2 and 251.1 MPa, yield strength (YS) ranged from 123.2 to 167.7 MPa, and elongation spanned 7.0–12.1% across the experimental matrix. The highest UTS and YS were recorded at a pin diameter of 8 mm, 900 rpm, and 50 mm/min welding speed, while moderate parameters provided more balanced elongation. ANOVA confirmed rotational speed and pin diameter as the most influential factors, whereas welding speed exhibited an inverse effect on strength. Microstructural analyses using EDS and EBSD further highlighted improved material flow in weld nugget with intermixing of materials. This reduces intermetallic formation and refinement underscoring UFSW’s potential to enhance Al–Cu joint performance.