This document analyzes parameters for friction stir welding (FSW) of dissimilar materials like aluminum and copper. It discusses the applications of aluminum to copper welding, the need for FSW over conventional welding due to advantages like reduced weight and corrosion resistance. The objective is to study the effects of FSW parameters like tool geometry and welding settings on the mechanical properties of aluminum-copper joints. Future work involves producing aluminum-copper composite material and examining how parameters affect properties.

1. ANALYSIS OF FSW PARAMETERS FOR
DISSIMILAR MATERIALS
Submitted by-
Nandan Kumar Singh (BE/5646/10)
Gaurav Verma (BE/5787/10)

2. CONTENT
• Introduction
• Application
• Need
• Objective
• Problem Statement
• Work Done upto Now
• Work Progress in Future
• Conclusion
• Reference

3. INTRODUCTION
FSW is emerging as a very efficient Solid-State joining/processing technique. FSW
is a solid-state joining technology, in which a rotating tool with a shoulder and a
pin moves along the faying surfaces of two rigidly clamped plates, faying surfaces
are the inner compressed sheet interfaces. The most convenient joint
configuration for FSW are Butt and Lap joints.
FSW Aluminium plate to copper plate

4. APPLICATION
Aluminium to copper welding is increasingly used in some practical applications
such as:-
1. Aircraft internal structure 2. Heavy dump and tank trucks
3. Fuel tank 4. Heat Transfer equipments
5.Electrical and electronic industry 6. Wiring
7. Electromobile equipments (battery in automobiles) etc.

5. NEED
FSW is preferred over conventional welding processes due to following reasons:-
• High reflectivity and thermal conductivity
• Formation of inter-metallic phases which lower the toughness
• Corrosion resistivity
• Fatigue resistivity
• Reduction in weight (approx. 20-50%)
• FSW is eco-friendly

6. OBJECTIVE
• Performing friction stir welding at Al and Cu plates
• Check process parameters involve in FSW process
 Tool geometry
 welding parameters
 Joint design
• Gain the knowledge about mechanical properties of different friction stir welds
between Al and Cu to enhance their use in industries

7. PROBLEM STATEMENT
 FSW involves complex material movement and plastic deformation. Welding
parameters, tool geometry and joint design exert significant effect on the
material flow pattern and temperature distribution, thereby influencing the
microstructural evolution of material.

8. WORK DONE UPTO NOW
Selection of material for the specimen :
- Aluminium (Al)
- Copper (Cu)
 Manufacturing technique :
- Friction Stir Welding (FSW)

9. WORK PROGRESS IN FUTURE
• To produce Al-Cu composite material
• To check the variation of parameters in FSW process on this specimen
-Tool geometry
-Welding parameters (rotation rate, traverse speed)
-Joint design (butt and lap joints)
• Comparison with the other engineering materials on the basis of
mechanical properties.

10. CONCLUSION
FSW process is an eco-friendly solid state joining technique compared to the
conventional welding techniques. The joining of aluminium to copper using FSW
has been reviewed to open a research window to researchers in order to expand
the technique to other aluminium and copper alloys with the aim of achieving
optimised parameters thereby leading to the commercialization of joints between
these materials. Research on friction stir welding between aluminium and copper
has not yet been thoroughly researched; much of the work has been focused on
welds characterizations and study of the material flow.

11. REFERENCE
• J.M. Timothy, “Friction Stir Welding of Commercially available
Superplastic Aluminium”, 2008, PhD thesis, Department of Engineering
and Design, Brunel University.
• B.S. Yilba, A.Z. Sahin, N. Kahraman , A.Z. Al-Garni, “Friction stir welding of
St-Al and Al-Cu materials” J. Mater. Process. Technol.,1995, 49, 431-443.
• H.B. Cary, Modern Welding Technology, Prentice-Hall, New Jersey, 2002.
• R. Rai, A. De, H. K. D. H. Bhadeshia and T. DebRoy, “Review: friction stir
welding tools”, Science and Technology of Welding and
Joining, 2011, 16, No 4, pp. 325- 342.
• J.E. Spowart, Z.Y. Ma, R.S. Mishra, in: K.V. Jata, M.W. Mahoney, R.S.
Mishra, S.L. Semiatin, T. Lienert (Eds.),Friction Stir Welding and Processing
II, TMS, 2003.