FRICTION STIR WELDING OF AA 6101-T64 AND COPPER: INVESTIGATION ON THE MECHANICAL AND ELECTRICAL PROPERTIES

Friction Stir Welding (FSW) has gained significant popularity as an advanced technology for joining both similar and dissimilar materials, especially in the context of aluminum alloys. This study provides an in-depth analysis of FSW, focusing on its applications in aluminum alloy welding, including the fundamental principles, tools, and equipment used in the process. Additionally, the paper discusses the benefits and challenges associated with FSW, as well as the various factors influencing weld quality. Specifically, the study aims to optimize input parameters to enhance the tensile strength, microhardness, and electrical resistivity of AA 6101-T64 weld joints with pure copper. The Response Surface Methodology (RSM) was employed to investigate three primary input factors at three distinct levels: tool rotational speed (840, 1045, and 1300[Formula: see text]rpm), traverse speed (25, 45, and 65[Formula: see text]mm/min), and tool pin offset (0.6, 1, and 1.2[Formula: see text]mm). The results demonstrated an improvement in tensile strength from 135[Formula: see text]MPa to 162 MPa. The microhardness distribution varied across the weld, with the highest hardness observed at the joint’s interface and lower values at the center. The electrical resistivity of the weld joints ranged from 0.027[Formula: see text][Formula: see text]m to 0.039[Formula: see text][Formula: see text]m, indicating a significant variation in material properties based on the optimized parameters. This study provides valuable insights into the precise control of FSW parameters to achieve high-performance joints, offering potential for further optimization in industrial applications. Furthermore, the findings contribute to a deeper understanding of the relationship between process parameters and the mechanical and electrical properties of welded joints, paving the way for future advancements in FSW technology.