• YANAMALA RAGAVENDRA
• Mr. N. PHANI RAJA RAO
• Mr. M.HEM SAGAR

The joining of dissimilar Aluminum Alloy and Copper aluminum plates of 5mm thickness was carried out by friction stir welding (FSW) technique. Optimum process parameters were obtained for joints using statistical approach. Five different tool designs have been employed to analyse the influence of rotation speed and traverse speed over the microstructural and tensile properties. In FSW technique, the process of welding of the base material, well below it’s melting temperature, has opened up new trends in producing efficient dissimilar joints. Effect of welding speed on microstructures, hardness distribution and tensile properties of the welded joints were investigated. By varying the process parameters, defect free and high efficiency welded joints were produced. The ratio between tool shoulder diameter and pin diameter is the most dominant factor. From microstructural analysis it is evident that the material placed on the advancing side dominates the nugget region. The hardness in the HAZ of 6061 was found to be minimum, where the welded joints failed during the tensile studies.

"PROCESS OF FRICTION STIRS WELDING OF ALUMINUM ALLOY AND COPPER DISSIMILAR METALS", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.12, Issue 8, page no.g147-g156, August-2025, Available :http://www.jetir.org/papers/JETIR2508619.pdf

"PROCESS OF FRICTION STIRS WELDING OF ALUMINUM ALLOY AND COPPER DISSIMILAR METALS", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.12, Issue 8, page no. ppg147-g156, August-2025, Available at : http://www.jetir.org/papers/JETIR2508619.pdf