Metallurgical investigation and mechanical properties of dissimilar friction crush welded Cu-Al sheets with flanged edge

Abstract Welding of dissimilar metals is one the most substantial requirements industries and extensively used in engineering applications. Dissimilar friction crush welding between oxygen-free copper (C1020) aluminum (1145-H1) sheets with a thickness 1 mm was investigated this work using different flange edge heights (2, 2.5 3 mm) gaps (0.5 Cu-Al sheets. Tool rotational speed 1500 rpm feed rate 120 mm/min were all experiments. Evaluation joints performed successfully optical microscope, SEM, XRD, EDS, hardness tensile tests. Several FCW experiments carried out to obtain optimum properties by adjusting flanged height gap Cracks are main defect encountered joints. The XRD results showed that no new reaction phases formed EDS pronounce diffusion elements zone mechanical coalescence responsible for welding. also indicated parameters has significant effect on strength