A Brief Review of Friction Stir Welding Between Dissimilar Aluminium
Alloy and Pure Copper
1Pratikrajsinh Gohil,2Unnati Joshi,3Tejas Vyas
123Department of Mechanical Engineering,1PG Student,2Associate Professor,
3Assistant Professor
123 Parul Institute of Technology, Vadodara, Gujarat
Abstract
Friction Stir Welding (FSW) is a solid state welding process capable of welding dissimilar materials such as aluminum and copper having wide range of industrial applications. The welding process is
widely used because it produces quality welds with good joint strength exhibiting none or a few amount
of intermetallic compounds. Copper and aluminum dissimilar joining is important for taking advantage of properties of both the materials such as electrical conductivity, thermal conductivity and corrosion
resistance. In this paper we review the research work done in past between aluminum and copper
joining by friction stir welding with a focus on resulting weld mechanical properties and microstructure
by optimization of the process parameters and FSW tool pin positioning such as tool pin offset, tool tilt angle and tool design features with a view for dissimilar aluminum and copper joining. It also includes
the future research in this field of welding.
Keywords – Friction stir welding, aluminium, copper, dissimilar materials, optimization, mechanical
properties and microstructure.
I. INTRODUCTION
Producing a good quality weld between dissimilar materials such as copper and aluminium with a good
joint strength is a challenging and complicated task for researchers and engineers. In the current
competitive world of industrial development that need requirement of different and various properties in a
single component or a part that can only be fulfilled by the effective joining of two dissimilar materials.
Aluminium and copper possess good electrical conductivity, thermal conductivity and corrosion
resistance that make them applicable for producing parts or components that require good electrical and
thermal conductivity for its application. Friction stir welding is an effective solid state welding technique
that can efficiently produce a good quality weld between the dissimilar materials. The capability of
friction stir welding to join separate dissimilar materials without melting is a unique feature of friction stir
welding. Friction Stir Welding (FSW) is a solid–state joining technique invented by The Welding
Institute (TWI) in 1991 for welding of ferrous and non–ferrous metals. Recently the technique is also
used for welding of polymer materials as well as welding between a metallic material and polymer. FSW
has developed as a huge improvement in metal joining in recent decade and is capable of welding
materials such as aluminium alloys, copper alloys, titanium alloys, mild steel, stainless steel and
magnesium alloys.
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A) Principle of operation.
Friction stir welding employs a non consumable rotating welding tool that has a probe or a pin that
extends below a shoulder which is fully penetrated between the two adjacent mating surfaces of the
workpieces as shown in fig 1. As the tool is traversed along the joint line, it mechanically pressurizes and
forges the two pieces of metal. Heat is formed by the friction between the revolving tool and the
workpiece material, which develops a soft region near the FSW tool of metal, and forges the hot and
softened metal by the mechanical pressure. Stirring of the tool along the joint line in traverse direction
uniformly joins the two edges of the adjacent workpieces as a result of welding. Advancing sides and the
retreating sides are the two different sides of the two work samples.
Fig. 1 Principle of operation of FSW [1]
B) FSW Tool
The FSW tool plays a significant and vital role for effective joining and leading the material flow
along the joint line along the traverse direction. The FSW tool consists of three parts: a shank,
shoulder and the pin or a probe with shoulder and pin the main parts of the tool as the shoulder
makes full contact on the upper surface of the interface at the joint line with the pin which is fully
inserted into the workpiece. Different tool design and geometry exhibit different mechanical
properties and microstructure of the welded joint due to the variation in tool geometry and is
majorly responsible for quality of weld. Thus the FSW tool is better known as the heart of the
joining process.
The following are the different types of tools used in friction stir welding are:
1) Straight Cylindrical
2) Threaded Cylindrical
3) Tapered Cylindrical
4) Square
5) Triangle
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Fig.2 Basic FSW tool pin profiles [2] Fig.3. Schematic View of FSW Tool [3]
C) Friction stir welding process parameters :
Tool rotation and traverse speeds
There are two types of tool speeds in friction-stir welding process as the velocity at which the tool
rotates and velocity at which it moves or traverses down the interface. The above two parameters
have significant importance and must be chosen with care to make sure a successful and efficient
welding cycle. The relationship between the rotation speed, the welding speed and the heat input
during welding is complex but it can be said that increasing the rotation speed or decreasing the
traverse speed will result in a hot weld.
Tool tilt and plunge depth
The plunge depth is defined as the depth of the lowest point of the shoulder below the
surface of the welded plate and has been seen as a basic parameter for guaranteeing weld
quality. As we plunge the shoulder below the plate surface it increase the pressure
beneath the tool and helps ensure adequate forging of the material. As we tilt the tool by
2–4 degrees, such that the rear of the tool is lower than the front, has been found to assist
the weld bonding for good joint strength for dissimilar FSW of aluminium and copper
Tool pin offset
The tool pin offset is defined as the offset of the tool pin from the weld centerline towards a
particular base material. Zero tool pin offset means the welding tool axis is exactly at the
centerline of the interface between the two welded work samples. It is recommended that the
conventional method of FSW welding where pin is inserted at the weld centre line produced poor
and imperfect joints in dissimilar FSW [4, 5,6,7,8]
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II. PAST STUDIES ON FRICTION STIR WELDING BETWEEN ALUMINIUM
ALLOYS AND COPPER
A. Optimization of the process parameters
In a developing field of dissimilar material welding optimization will be considered as a
significant technique to improve its application fields. Optimization deals with obtaining
process parameters accurately to certain value from a series of values having long range. So
accurate value achievement will reduce cost and also develop and improve its output
parameters
Sachindra Shankar et al.[9] conducted friction stir welding of aluminium alloy 1050 to pure
copper joint by varying two values of rotational speed such as 1400 rpm and 2000 rpm and
two values of traverse speed such as 40 and 63 mm/min with 2mm tool pin offset and keeping
all the other parameters such as tool design and geometry and tool tilt angle as constant.
Mechanical tests such as tensile test, microhardness tests and FESEM tests were implemented
to inspect the joint strength and microstructural property respectively. It was concluded that
the optimum set of parameters include the tool rotational speed of 1400 rpm and tool traverse
speed of 63 mm/min fabricated defect free welded joints. Highest joint strength acquired was
approximately 91% of Al parent metal in weld nugget by taking the 2 mm offset of the tool
on the Al side and fine-grained microstructure was observed in the weld nugget
Nitish kumar et al. [10] evaluated tensile strength in friction stir welded aluminum alloy
6101-T6 and commercially pure copper joints by conducting an experimental study to
optimize the critical process parameters such as tool geometry, shoulder diameter to pin
diameter ratio, welding speed, rotational speed and pin offset on the tensile behavior of
friction stir welded between aluminum alloy 6101-T6 and commercially used pure copper
using Taguchi’s L 16 design of experiment. Thorough mixing of dissimilar materials in
nugget zone was observed corresponding to best experimental conditions resulting in the
maximum tensile strength of 181 MPa.
Weizhang et al. [11] analyzed friction stir welding of 6061 Al to T2 pure Cu adopting tooth-
shaped joint configuration on microstructure and mechanical properties of joint. In this work
dissimilar 6061aluminum alloy and commercial pure copper were friction stir butt welded
adopting tooth-shaped joint configuration to investigate the influence of Al/Cu content in
welding bead (WB) on the microstructure and mechanical properties of the joint. Macro and
microstructure of the cross section of the joints were characterized via optical microscopy
(OM) and Scanning Electron Microscopy (SEM). According to the tensile tests, the
maximum and minimum failure loads were 7.53KN and 5.56KN obtained.
V.C. Sinha et al. [12] evaluated microstructure and mechanical properties of dissimilar joints
of aluminum alloy and pure copper by (Friction stir welding) FSW at variable tool rotational
speeds from 150 to 900 rpm in steps of 150 rpm at 60 mm/min travel speed and constant tilt
angle 2°.The interfacial microstructures of the joints were characterized by optical and
scanning electron microscopy. The grain size of stir zone and heat affected zone for all the
joints increased with the increase in tool rotational speeds. The Al4Cu9, AlCu, Al2Cu and
Al2Cu3 intermetallic phases have been observed at the interface and stir zone region of
dissimilar Al/Cu joints. Thus the welded joint when processed at 600rpm tool rotational
speed achieved maximum ultimate tensile strength of ~77% of aluminum.
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M. Felix Xavier Muthu et al. [13] evaluated the material flow behavior of friction stir welding of AA1100 and pure copper under three pin profile whorl pin profile, plain taper pin profile
and taper treaded pin profile. Optical microscope, scanning electron microscope, X-ray
diffraction and EDS analysis were used to characterize the microstructural features. From
three pin profiles, the joints fabricated using plain taper pin profile result in better mechanical properties, with PTP result in yield strength of 101 MPa, tensile strength of 116 MPa and
joint efficiency of 68%.
Qiu-zheng ZHANG et al. [14] conducted dissimilar friction stir welding between 1060
aluminum alloy and annealed pure copper sheet with a thickness of 3 mm. It was observed
that pure copper and 1060 aluminum alloy were joined successfully by FSW at a rotation
rate of 1050 r/min and a welding speed of 30 mm/min with a configuration where copper is
located on advancing side, and most of the tool pin is inserted on the aluminum side. The
ultimate tensile strength of the joints is 148 MPa, failing across Cu/WN interface with a
brittle-ductile mixed fracture mode.
B. FSW tool pin positioning
The position of tool pin or probe is the most influencing and significant parameter that
governs the material flow and affects the weld quality for dissimilar Al to Cu FSW and it can
be divided into two parts:
(I) Tool pin offset: - The FSW tool movement from the center of the weld joint line towards
one of the two base plates is known as tool pin offset. No pin offset means the tool
centerline is exactly at the center of weld line between the two materials. The materials
such as aluminum and copper are very different from one another in conditions of physical
and mechanical characteristics like melting point and strength. So in such conditions of
material during FSW shifting the tool towards Al side is suggested as Cu having the
higher thermal expansion coefficient could not take away the larger amount of heat.
Provision of tool pin offset towards softer material side controls the formation of fragment
in the stir zone and promotes good stirring [15]. It is generally reported that the pin offset
towards the softer materials resulted in defect free joints [16, 17, 18, 19, 20].The optimum
value of tool offset depends upon the base material composition, thickness,
tool design and process parameters [22, 23−26]. The usage of 1.5−2 mm tool pin offset
was recommended in FSW of Al−Cu to attain good quality welding.
(II) Tool tilt angle: - The relative angular displacement of tool adjusted with reference to the
workpiece surface is known as the tool tilt angle. The position of tool when it is
perpendicular to the work surface then it is said to be zero tilt angle [27]. The tilt
angle of FSW tool contributes a major role with respect to weld joint quality [28-30]. It is
found that the bigger tilt angle gives a tight weld joint [30] and avoids the distribution
of work material on the top surface. It was reported that in FSW experimental work
between AA 2024 and pure copper with a 2° tilt angle of tool gives high strength as
compared to 0° because increase of tilt angle from 0° to 2° serve a free flow of particles
of Copper in aluminum matrix[24]. In one more research work of dissimilar FSW
between AA6061−T651 and Cu [27], tool tilt angle ranging from 2° to 4° was suggested.
As a result, it is important to recognize the optimum tool tilt angle for FSW of Al and Cu.
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(III) FSW tool design features: - FSW tool is known as the heart of the welding process and
its main work is to provide appropriate heat and soft the workpiece materials by stirring
action at the interface of two workpiece. The FSW tool design consists of a shoulder and
a pin in which the shoulder generates the maximum heat input that is upto 80% riding
above the plate surface creating friction on the top portion of the plate and the pin which
is fully inserted inside the work piece at its interface. The main features of the
shoulder and pin are their diameters, surface profile, geometry and type of
surface [31].
Tool Shoulder: - The tool shoulder diameter is the vital part of the tool as it is
responsible for major heat generation and defect free welding which should be selected
carefully for dissimilar Al to Cu FSW. In dissimilar FSW of Al−Cu, microstructure
and mechanical properties, material deformation, IMCs development and plunge load
variation are affected by the type of tool used. Heat formation and resulting peak
temperature rising are mostly influenced by shoulder diameter and geometry
during FSW [32, 33].
Kush P. Mehta and Vishvesh J. Badheka [34] investigated and analyzed nine
different tool designs for dissimilar friction stir welding between aluminum and copper, while the rest of the process parameters were kept constant. Mechanical and
metallurgical tests such as macrostructure, microstructure, tensile test, hardness,
scanning electron microscope and electron X-ray spectrographs were performed to
assess the properties of dissimilar joints. The results exhibited that, the maximum joint
strength was achieved by the tool of cylindrical pin profile having 8 mm pin diameter.
Maximum hardness of HV 283 was obtained at weld made by the polygonal square pin
profile. It is found that small shoulder diameter along with large pin offset results in
continuous cavity defect (tunnel) and the combination of small shoulder diameter with
high welding speed results in a surface crack defect [35].
Tool shoulder design is the main aspect during FSW. Shoulder surface can be flat or
conical. Flat, convex and concave are the most important types of usually used shoulder
end surface profile. The ending surface of the shoulder might consist a variety of features
like grooves, scrolls, ridges, knurling and concentric circles to assist better mixing of
material [36, 37]. The shape of tool shoulder and its geometry have considerable effect
on the material flow system, weld bead shape and size, mechanical properties and
microstructure and on the development of IMCs for the dissimilar aluminum and copper
FSW. The choice of optimum feature of the shoulder is decided by the
work thickness and work piece and tool materials. Owing to few research articles,
designing of good and suitable shoulder features in dissimilar FSW of Al and Cu is still a
wide area of research.
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Fig 4. Different types of shoulder shapes and surface features [38]
Tool pin: - The tool pin is the extended part of the tool shoulder with diameter less than
the tool shoulder diameter and the pin is main part of the tool that stirs and causes the
movement of material from advancing side to retreating side. The progress of tool pin
in the work piece causes shearing the material in front of tool and forces it behind the
tool. The main function of the revolving tool pin is to cause shearing the material in
front, giving stirring action to the deformed material and to move this stirred material
at the back of the tool for consolidating the joint. The geometry of the pin profile
governs the feed rate or welding speed of tool and is the main factor affecting
mechanical properties and microstructure [34].The most required design criteria features
of tool pin for dissimilar FSW of Al and Cu are pin length, pin diameter and surface
profile of pin. It is necessary during friction stir welding process to have appropriate and
sufficient contact of the tool shoulder with base work plates by proper axial plunge load
which is maintained by always keeping pin length 0.2-0.3 mm less compared to
workpiece thickness [1].
M. Felix Xavier Muthu et al. [13] studied material flow behavior of friction stir welding
of AA1100 and pure copper under three pin profile whorl pin profile, plain taper pin
profile and taper treaded pin profile and its effect on microstructure, microhardness and
tensile properties were analyzed. Optical microscope, scanning electron microscope, X-
ray diffraction and EDS analysis were used to characterize the microstructure features.
Among the three pin profiles, plain taper pin profile results in defect-free stir zone and
maximum joint properties of yield strength of 101 MPa, tensile strength of 116 MPa and
joint efficiency of 68% compared with the other pin profiles. However, the microhardness
plots are more or less identical for all the pin profiles but follows fluctuating trend.
The different types of pin shapes and profile are shown in fig 5.
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Fig 5. Different types of pin shapes and profile [39]
The diameter of the shoulder and the pin diameter share a relation with each other known
as Shoulder diameter to pin diameter ratio (SPR). SPR value depends on type of alloy of
aluminium and work piece thickness. SPR is comparatively high for dissimilar welding
compared to with similar welding. The high SPR taken throughout FSW of Al−Cu
increases the heat generated and this bigger heat can be efficiently distributed by
controlling other process parameters, i.e., arrangement of workpieces, tool pin offset,
traverse speed and rotational speed. In dissimilar friction stir welding of larger work
piece thickness higher SPR is required.
C. Mechanical characterization and microstructure
Many of researchers concentrated on mechanical properties such as tensile strength, hardness
and bending strength of friction stir welded specimens to form a good quality welded joint
that can be given practical application such as electrical and thermal applications. Also
microstructure of friction stir welded joint was studied to see formation of aluminium and
copper intermetallic compound formation as well as Al Cu phases in weld nugget zone so that
researchers can get idea of formation of microstructure for dissimilar aluminium to copper
friction stir welding.
Radmir Rzaev et al. [40] studied friction stir welding of dissimilar joints of copper M1, M3
and aluminum AD1 (AMg6) alloys of 3 mm thickness. The microstructure, mechanical
properties and phase components of welded joints obtained by FSW were studied using
various methods of metal physical analysis including X-ray diffraction, mechanical tests for
tearing and bending. Copper (M1) and aluminum alloy (AD1) of butt joints are welded by
FSW with the following parameters of the mode: speed of rotation of 900 rpm, welding speed
25 mm/min, tool angle of 3 degrees, copper is located on the advancing side, and most of the
tool pin offset on the copper part. The average hardness values in the WN are higher than for
the being welded metals, probably because of the high density of dislocations and the
accumulation of grain boundaries formed during the lifetime of the regime SPD upon contact
with the tool pin.
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Prakash Kumar Sahu et al. [41] conducted dissimilar friction stir welding between aluminium
1050 alloy and pure copper plates by varying different process parameters such as rotational
speed of 600rpm to 2400rpm in interval of 600 rpm, feed rate ranging from 20 to 40 mm/min
and tool offset ranging from 0.5 to 2mm towards aluminium side. Mechanical Properties and
Microstructures of dissimilar Al/Cu friction Stir welding Joints were investigated and it was
found that defect free joint can be obtained, when the hard Cu plate is placed on the
advancing side while large volume defects are observed when Al plates is placed on the
advancing side. Also pin offset of not less than 1.5 mm towards soft Al matrix leads to defect
free joint and good metallurgical bonding between the Al and Cu. At smaller pin offset, the
defects arise due to high Cu percentage in the welded zone. At tool rotation rate of 1200
rev/min, welding speed of 30 mm/min, 0.1 mm plunging depth and 1.5 mm offset towards Al
alloy yield highest ultimate tensile strength of 126.0 MPa and yield strength of 119.3 MPa
which constitute 95% and 100%, respectively, of the 1050 Al base metal was obtained. SEM
morphologies of the fracture surfaces indicate that the type of fracture was not purely ductile
which leads less tensile strength. The XRD analysis indicates the presences of the various
IMCs and the line scan indicates the mixed flow of Al/Cu material
M. Felix Xavier Muthu et al. [42] studied tool travel speed effects on the mechanical
properties and microstructure of friction stir welded aluminum–copper joints. In this research
work conducted friction stir welding of aluminum and copper were carried out by varying the
tool travel speed from 50 mm/min to 90 mm/min. The joint properties were evaluated and
characterized with respect to the stir zone formation, intermetallic formation and its
distribution. Tool traverse speed of 70 mm/min and 80 mm/min resulted in the optimum
range of heat input to form defect free stir zone and the joint fabricated at tool travel speed of
80 mm/min results in higher tensile strength and joint efficiency of 113 MPa and 70.62%
respectively. The optimal heat contribution is low enough to decrease the diffusion between
Al–Cu interfaces, which outcome in the thin intermetallic thickness of 1.9µm. The nano
scaled thin continuous intermetallics of Al2Cu, AlCu and Al4Cu9 give high tensile strength.
H. Barekatain et al. [43] conducted friction stir welding of Severely Plastic deformed
Aluminum AA 1050 and Commercially Pure Copper Sheets. The annealed and severely
plastic deformed sheets were subjected to friction stir welding (FSW) at different rotation and
traverse speeds. Cu was placed in advancing side. Constant offset of approximately 1 mm
was used toward Al side for all welds. AA 1050 aluminum alloy and commercially pure
copper has been joined successfully by FSW in annealed and CGPed conditions. Several
forms of intermetallic compounds are found in weld zone of FSWed annealed and CGPed
samples. These compounds mainly consist of Al2Cu and Al4Cu9. In tensile test results,
generally the weakest part of weld joints of annealed and CGPed samples are Al base metal
and stir zone, respectively.
LI Xia-wei et al. [44] conducted the dissimilar friction stir welding of pure copper/1350
aluminum alloy sheet with a thickness of 3 mm and mechanical properties and microstructure
of formed weld nugget were analyzed Most of the rotating pin was inserted into the
aluminum alloy side through a pin-off technique. Sound welds were obtained at a rotation
speed of 1000 r/min and a welding speed of 80 mm/min. The hardness at the copper side of
the nugget is higher than that at the aluminum side. The hardness at the bottom of the nugget
is generally higher than other regions. The UTS and elongation of the dissimilar joints are
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152 MPa and 6.3%, respectively, and the dissimilar joints fail in a ductile-brittle mixed
fracture mode. Also no intermetallic compound is found according to the XRD results.
Complex vortex-like and swirl patterns are formed in the dissimilar FSW joint. The lamella
structure in the bottom of the nugget is more homogeneous and finer than other regions.
P. Xue et al. [45] carried out the work on friction stir welding of butt joints of 1060 aluminum
alloy and commercially pure copper and the effect of welding parameters on surface
morphology, interface microstructure and mechanical properties was investigated. It was
concluded that sound defect-free joint could be obtained only when the hard Cu plate was
fixed at the advancing side. A large volume defect was observed when the soft Al plate was
fixed at the advancing side. Sound defect-free joints were obtained under the larger pin
Offsets of not less than 2mm to the Al matrix, and a good metallurgical bonding between the
Cu bulk/pieces and Al matrix was achieved. Sufficient reaction were achieved in the FSW
Al–Cu joints produced at higher rotation rates between 800 and 1000 rpm and proper pin
offsets of 2 and 2.5mm, resulting in the good tensile properties. The joints produced at
600rpm under a pin offset of 2mm showed sound bending properties.
III. CONCLUSIONS AND FUTURE WORK:-
The welding of aluminum and copper by friction stir welding has been briefly reviewed in form
of various aspects such as optimization of different process parameters such as rotational speed,
welding speed, different tool design and geometry aspects, FSW tool pin positioning such as
tool pin offset and tool tilt angle, and its effects on mechanical properties such as tensile
strength, hardness of welded joint and also microstructure study of the
formed weld nugget to open a research window to researchers with a view to expand the
welding process to other aluminum and copper alloys with the view of achieving optimized
welding parameters. Research on friction stir welding of aluminum alloy to copper has
still not been comprehensively researched. Also adding, there is a need of comprehensive
information of tool design criteria and tool material for various thicknesses and alloys of this
welding process. But there is still, a strong requirement in increasing the industrial applications
of friction stir welding between aluminum alloy and copper in the manufacturing area.
Thus, the applications of the friction stir welding method to weld aluminium alloy and copper
alloys and various material shapes is of significance in the growth of their industrial
applications. In above review, the friction stir welding of dissimilar materials
concentrating on aluminium alloys and copper has been successfully carried out. It will
present complete overview for the current and also offer the current state of research on
friction stir welding between aluminium alloys and copper to fill the gaps with new
research ideas.
Also, the novel and different tool design such as the double shoulder bobbin tool design
having two shoulders one riding on the upper side of the plates to be welded and another on
lower side with a pin in between the two shoulders which is fully within the work plates to be
welded has still not yet been worked in past for dissimilar materials. The double sided friction
stir welding using a bobbin tool design has been employed for similar materials in FSW
especially for similar aluminium alloys. Improvisation in mechanical properties of welded joint
and microstructure formation can be worked out with the help of double shoulder bobbin tool
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which has the benefit of generating a processed region in the workpiece having
rectangular cross section, as opposite to the triangular zone which is most probably
established when conventional friction stir welding tool designs are used. Also, the total axial
force on the work piece is approximately zero, which has major useful implications in machine
design and cost.
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Volume 10 Issue 4 - 2020
ISSN: 1548-7741
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