Parametric optimization of Friction Stir Welding on Aluminium alloy and Copper with Different Filler Material

Abstract

Abstract newlineWeldingstandsasacornerstoneprocessinfabricationandmanufacturing.Itsubiquity stems from its unique ability to meld materials together, creating unified structures that form the backbone of countless industries, from aerospace to automotive, construction to shipbuilding. As our world becomes increasingly interconnected and reliant on a diverse array of materials, the importance of effective and versatile weldingtechniquesbecomesevermorepronounced.Asindustriesgrowanddiversify, so does the demand for welding techniques that can address the intricate and multifaceted needs of materials joining. newlineOne such technique that has garnered considerable attention and acclaim is Friction Stir Welding (FSW). Unlike traditional welding methods that rely on the fusion of materials through the application of heat, FSW operates on a fundamentally different principle. It leverages the concept of mechanical stirring, essentially quotmixingquot the materials together while they are in a plasticized state. This novel approach avoids many of the pitfalls associated with conventional welding, such as the introduction of impurities, excessive heat-affected zones, and weld defects. newlineThe implications of FSW are profound. Not only does it promise to revolutionize the welding industry, but it also holds the potential to unlock new possibilities in material joining. Its versatility extends to a wide range of materials, from metals likealuminum and copper to nonmetals, polymers, and even composite materials. This adaptability positions FSW as a potent tool in the hands of engineers and researchers seeking to overcome the challenges posed by increasingly complex material requirements. newlineWithin this context, the specific focus of our research emerges joining dissimilar materials through FSW. We are tasked with the formidable challenge of uniting aluminum alloy and copper, two materials that are inherently dissimilar in terms of their properties and behaviors. The motivation for this investigation arises from the real-world applications where such d