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Optimal FSW Process Parameters to Improve the Strength of Dissimilar AA6061-T6 to Cu Welds with Zn Interlayer

Dissimilar welding of Al-Cu has many potential applications in electric power, electronic and piping industries due to high corrosion resistance, heat and conducting properties. Weld joints through friction stir welding (FSW) process are free from melting- and solidification-related defects. Compared to the recently used Box–Behnken design of response surface methodology, a simple and reliable modified Taguchi design of experiments is utilized for the dissimilar welding of AA6061-T6 to Cu with Zn interlayer to obtain the optimal FSW process parameters and the expected range of strength properties. Empirical relation for the tensile strength is developed in terms of FSW process parameters (viz., tool rotation speed, tool travel speed and tool pin offset) and validated through test results. Most of the test data are within the expected range.