Effect of Process Parameters on Tensile Properties of Friction Stir Weld of Dissimilar Pure Copper to 6061-T6 Aluminum Alloy

Friction stir welding is a solid state welding process where material gets plastically deformed due to generation of frictional heat between the surfaces of the plates to be joined and the FSW tool. Various Aluminium alloys have been successfully welded using FSW. So presently FSW of dissimilar materials is now challenging research work to produce sound defect free welds with less intermetallic compounds, Such as Aluminium to copper, which differ in their mechanical properties but have a wide application in aerospace industries. So the present work is based on feasibility and effect of different process parameters upon tensile strength of dissimilar weld of 6061-T6 aluminium alloy with pure copper. In this study the maximum tensile strength of the weld was achieved using threaded tool with 1000 RPM tool rotational speed and 25mm/min weld speed.