Abstract: This paper reports the tensile fracture location
characterizations of dissimilar friction stir welds between 5754
aluminium alloy and C11000 copper. The welds were produced using
three shoulder diameter tools; namely, 15, 18 and 25 mm by varying
the process parameters. The rotational speeds considered were 600,
950 and 1200 rpm while the feed rates employed were 50, 150 and
300 mm/min to represent the low, medium and high settings
respectively. The tensile fracture locations were evaluated using the
optical microscope to identify the fracture locations and were
characterized. It was observed that 70% of the tensile samples failed
in the Thermo Mechanically Affected Zone (TMAZ) of copper at the
weld joints. Further evaluation of the fracture surfaces of the pulled
tensile samples revealed that welds with low Ultimate Tensile
Strength either have defects or intermetallics present at their joint
interfaces.
Abstract: Friction Stir Welding (FSW) is a solid state welding
process invented and patented by The Welding Institute (TWI) in the
United Kingdom in 1991 for butt and lap welding of metals and plastics. This paper highlights the benefits of friction stir welding
process as an energy efficient and a green technology process in the
field of welding. Compared to the other conventional welding processes, its benefits, typical applications and its use in joining
similar and dissimilar materials are also presented.