Investigation of FSSW parameters on shear fracture load of AA6061 and copper alloy joints

In this research, Friction stir spot welding (FSSW) is extensively employed to join dissimilar metals consisting of AA6061-T6 Aluminium Alloy and Commercial Copper Alloy. These alloys were friction stir spot welded using process parameters with the major impact, such as Dwell Time (DT), Rotational Speed (RS), Plunge Rate (PR) and Tool Diameter Ratio (D/d). Trail experiments have been carried out using Design of Experiments. Sound welded joints exhibiting a maximum shear fracture load of 4.79 kN were obtained at a RS of 2000 rpm, PR of 7 mm/min, DT of 25 s and D/d of 3.5, Balanced material flow around the pin was also observed at this condition, and it is evident that the superior metallurgical properties and geometric features at this condition results in the higher strength. Moreover, the joint also exhibited higher load-bearing capabilities due to an optimal hook height of 0.89 mm, hook width of 1.3 mm and hook initiation distance of 1.4 mm. The continuous formation of intermetallic compound such as ɤ₂-Cu₉Al₄ in the Cu zone and ɳ₂-CuAl in the Al zone may also enhance the shear fracture load.