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Effect of process parameters on microstructure and electrical conductivity during FSW of Al-6101 and Pure Copper
Abstract
Copper (Cu) is predominantly used material as a conducting element in electrical and electronic components due to its high conductivity. Aluminum (Al) being lighter in weight and more conductive on weight basis than that of Cu is able to replace or partially replace Cu to make lighter and cost effective electrical components. Conventional methods of joining Al to Cu, such as, fusion welding process have many shortcomings. Friction Stir Welding (FSW) is a solid state welding process which overcomes the shortcoming of the fusion welding. FSW parameters affect the mechanical and electrical properties of the joint. This study aims to evaluate the effect of different process parameters such as shoulder diameter, pin offset, welding and rotational speed on the microstructure and electrical conductivity of the dissimilar Al-Cu joint. FSW is performed using cylindrical pin profile, and four process parameters. Each parameter at different levels is varied according to Taguchi’s L 18 standard orthogonal array. It is found that the electrical conductivity of the FSWed joints are equal to that of aluminum at all the welded sections. FSW is found to be an effective technique to join Al to Cu without compromising with the electrical properties. However, the electrical conductivity gets influenced by the process parameters in the stir zone. The optimal combination of the FSW parameters for maximum electrical conductivity is determined. The analysis of variance (ANOVA) technique applied on s…
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“The most common practice employs four-point resistance measurements [11][12][13][14][28][29][30][31][32][33][34][35], while in some cases (typically thin sheets) an eddy current resistivity measurement technique is used [18,36].”
From Electrical and thermal stability of Al-Cu welds: Performance benchmarking of the hybrid metal extrusion and bonding process (2022) · cites this paper as [36]
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Cited by
Sorted by citations
A Review on Laser-Assisted Joining of Aluminium Alloys to Other Metals
Bunaziv, I., Akselsen, O. M., Ren, X., Nyhus, B., Eriksson, M., & Gulbrandsen-Dahl, S. (2021) · Metals · doi:10.3390/met11111680 · Cited by 48
Elkjaer, A., Sørhaug, J. A., Ringen, G., Bjørge, R., & Grong, Ø. (2022) · Journal of Manufacturing Processes · doi:10.1016/j.jmapro.2022.04.029 · Cited by 23
Metadata
- Authors
- Sharma, N., Khan, Z. A., Siddiquee, A. N., Shihab, S. K., & Wahid, M. A.
- Affiliations
- Jamia Millia Islamia (IN)
- University of Diyala (IQ)
- Corresponding author
- Sharma, Nidhi
- Venue
- Materials Research Express
- Publisher
- IOP Publishing
- Published
- 2018-04-18
- Volume
- 5
- Issue
- 4
- Pages
- 046519
- ISSN
- 2053-1591 (ISSN-L)
- OpenAlex
- W2796317640
- Cited by
- 24
- References
- 0
- Citations by year
- 2026: 2 · 2025: 1 · 2024: 2 · 2023: 2 · 2022: 3 · 2021: 3 · 2020: 3 · 2019: 5 · 2018: 3
- FWCI
- 2.24
- Type
- journal article
- Language
- en
- Open access
- closed
- Licence
- Locations
- Materials Research Express (publishedVersion)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Advanced Welding Techniques Analysis
- Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
- Physical Sciences › Materials Science › Metals and Alloys › Aluminum Alloy Microstructure Properties
- Keywords
- friction stir welding, pure copper, electrical conductivity, microstructure, process parameter optimization, shoulder diameter, rotational speed, stir zone, solid-state welding, Taguchi orthogonal array
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