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Welding of dissimilar metals is one of the most substantial requirements of industries and extensively used in engineering applications. Dissimilar friction crush welding between oxygen-free copper (C1020) and aluminum (1145-H1) sheets with a thickness of 1 mm was investigated in this work using different flange edge heights (2, 2.5 and 3 mm) and gaps (0.5 and 1 mm) between Cu-Al sheets. Tool rotational speed of 1500 rpm and feed rate of 120 mm/min were used in all welding experiments. Evaluation of Cu-Al joints was performed successfully using optical microscope, SEM, XRD, EDS, hardness and tensile tests. Several FCW experiments were carried out to obtain the optimum properties by adjusting the flanged edge height and gap between dissimilar sheets. Cracks are the main defect encountered in Cu-Al joints. The XRD results showed that no new reaction phases were formed in the Cu-Al joints. EDS results showed no pronounce diffusion of elements in the crush zone and mechanical coalescence was responsible for welding. The results also indicated that the FCW parameters has a significant effect on the hardness and tensile strength of Cu-Al joints.

Metallurgical investigation and mechanical properties of dissimilar friction crush welded Cu-Al sheets with flanged edge