Experimental study demonstrates rotational speed-dependent mechanical strength in copper-sandwiched aluminum weld joints, highlighting structural trade-offs and corrosion risks.
Aluminum alloys and their composites are widely used in the automotive, aerospace, and construction industries for the manufacture of various parts and components. Friction stir welding is a unique and innovative method for joining similar and dissimilar materials/components without increasing their weight. Various researchers have reported FSW of Al–Cu dissimilar materials. However, sandwiching of Cu material between the joining edges has not yet been reported. The novelty of this study lies in introducing a Cu sandwich between the joining edges and investigating its effect on the joint properties of an Al-1120 plate welded by friction stir welding. Welding is carried out at tool rotational speeds of 900, 1400, and 2240 rpm, and at a constant transverse speed of 27 mm/min, using a conical-threaded pin profile FSW tool. The properties of sandwiched and unsandwiched weld joints were compared. The result reveals that weld joints fabricated at 1400 rpm exhibit higher tensile strength. Higher flexural strength was observed in weld joints fabricated at 2240 rpm. Furthermore, the wear behaviour of weld joints fabricated at 1400 rpm exhibits superior. It is strongly recommended that Cu sandwich joints not be used in applications where corrosion is suspected.
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Gupta et al. (2026) studied this question.
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