1. ANALYSIS OF FSW PARAMETERS FOR DISSIMILAR MATERIALS Submitted by- Nandan Kumar Singh (BE/5646/10) Gaurav Verma (BE/5787/10)

2. CONTENT Introduction Application Need Objective Problem Statement Work Done upto Now Work Progress in Future Conclusion Reference 3. INTRODUCTION FSW is emerging as a very efficient Solid-State joining/processing technique. FSW is a solid-state joining technology, in which a rotating tool with a shoulder and a pin moves along the faying surfaces of two rigidly clamped plates, faying surfaces are the inner compressed sheet interfaces. The most convenient joint configuration for FSW are Butt and Lap joints. FSW Aluminium plate to copper plate 4. APPLICATION Aluminium to copper welding is increasingly used in some practical applications such as:- 1. Aircraft internal structure 2. Heavy dump and tank trucks 3. Fuel tank 4. Heat Transfer equipments 5.Electrical and electronic industry 6. Wiring 7. Electromobile equipments (battery in automobiles) etc. 5. NEED FSW is preferred over conventional welding processes due to following reasons:- High reflectivity and thermal conductivity Formation of inter-metallic phases which lower the toughness Corrosion resistivity Fatigue resistivity Reduction in weight (approx. 20-50%) FSW is eco-friendly 6. OBJECTIVE Performing friction stir welding at Al and Cu plates Check process parameters involve in FSW process Tool geometry welding parameters Joint design Gain the knowledge about mechanical properties of different friction stir welds between Al and Cu to enhance their use in industries 7. PROBLEM STATEMENT FSW involves complex material movement and plastic deformation. Welding parameters, tool geometry and joint design exert significant effect on the material flow pattern and temperature distribution, thereby influencing the microstructural evolution of material. 8. WORK DONE UPTO NOW Selection of material for the specimen : - Aluminium (Al) - Copper (Cu) Manufacturing technique : - Friction Stir Welding (FSW) 9. WORK PROGRESS IN FUTURE To produce Al-Cu composite material To check the variation of parameters in FSW process on this specimen -Tool geometry -Welding parameters (rotation rate, traverse speed) -Joint design (butt and lap joints) Comparison with the other engineering materials on the basis of mechanical properties. 10. CONCLUSION FSW process is an eco-friendly solid state joining technique compared to the conventional welding techniques. The joining of aluminium to copper using FSW has been reviewed to open a research window to researchers in order to expand the technique to other aluminium and copper alloys with the aim of achieving optimised parameters thereby leading to the commercialization of joints between these materials. Research on friction stir welding between aluminium and copper has not yet been thoroughly researched; much of the work has been focused on welds characterizations and study of the material flow. 11. REFERENCE J.M. Timothy, Friction Stir Welding of Commercially available Superplastic Aluminium, 2008, PhD thesis, Department of Engineering and Design, Brunel University. B.S. Yilba, A.Z. Sahin, N. Kahraman , A.Z. Al-Garni, Friction stir welding of St-Al and Al-Cu materials J. Mater. Process. Technol.,1995, 49, 431-443. H.B. Cary, Modern Welding Technology, Prentice-Hall, New Jersey, 2002. R. Rai, A. De, H. K. D. H. Bhadeshia and T. DebRoy, Review: friction stir welding tools, Science and Technology of Welding and Joining, 2011, 16, No 4, pp. 325- 342. J.E. Spowart, Z.Y. Ma, R.S. Mishra, in: K.V. Jata, M.W. Mahoney, R.S. Mishra, S.L. Semiatin, T. Lienert (Eds.),Friction Stir Welding and Processing II, TMS, 2003.