Effects of Tool Structure and Process Parameters in Friction Stir Welding on the Temperature and Mechanical Properties of Dissimilar Copper–Aluminium Welded Joints

Friction stir welding (FSW) is a solid-state welding method. The effects of tool structure, tool rotational speed, and welding speed in friction stir welding on the temperature, microstructure, and mechanical properties during the welding of 3 mm thick 6061-T6 aluminium alloy and T2 pure copper plates were investigated through experiments, numerical simulations, mechanical property tests, and microstructural observations, with the aim of enhancing welding strength and efficiency. The results showed that the welding heat input increased with the shoulder and pin diameters. When the shoulder diameter was in the range of 10–16 mm, proportional increases in the pin diameter resulted in an approximate increase of 30 °C in the weld centre temperature for every 2 mm increase in shoulder diameter. Compared to welding speed, rotational speed had a more significant effect on the heat input. Compared to the smooth tool, the threaded tool promoted the dispersion of copper particles within the aluminium matrix, facilitating the formation of Al2Cu phases. This increased the tensile strength of the weld joint from 183 to 236 MPa (a 28.9% improvement), along with a 57% increase in the weld centre hardness. An energy-dispersive X-ray spectroscopy analysis indicated that welding with the threaded tool resulted in the presence of significantly hard and brittle intermetallic compounds, including AlCu and Al2Cu, in the stirring zone, which substantially enhanced the weld strength.