The effect of welding speed on dissimilar joint aluminum-copper plate friction stir welded joint Available to Purchase

Fusion welding is less effective when joining dissimilar materials like copper and aluminum because it results in compaction flaws like porosity and hot cracking. The solid-state welding method, or welding in a solid state, is more effective in this case because combining aluminum and copper materials with the solid state can reduce metallurgical processes that happen at high temperatures. A5005 aluminum and C10100 copper plates with dimensions of 150 mm × 150 mm × 3 mm were the materials employed in this work. The St 90 high carbon steel utilized for the friction stir welding (FSW) welding tool has dimensions of 18 mm for the shoulder diameter and 4 mm for the pin diameter. The FSW dissimilar aluminum-copper welding process was carried out using the Aciera AS 1 milling machine, with welding speed variations of 25 mm/min, 50 mm/min, 75 mm/min, and 100 mm/min. Other process parameters, such as pin geometry and rotational speed, are held constant in a cilynder form and around 910 rpm, respectively. Afterward the dissimilar aluminum 5005 and copper welded joint was evaluated by several testing. These tests included tensile testing according to the ASTM E8 standard, hardness testing, and metallography testing. According to the findings of this study, the hardness value in the HAZ and stir zone increases with the welding speed used. The aluminum HAZ, copper HAZ, and stir zone all recorded values of 42.7 VHN, 55.9 VHN, and 68.9 VHN, respectively, for the highest hardness value at a variation of 100 mm/min. The joint strength increases with increasing welding speed, reaching up to 43.66 MPa at 75 mm/minute welding speed with minimal weld defect, after which the strength decreases with increasing welding speed.