Prediction and validation of intermetallic compound formation during friction stir welding of AA6061 to commercially pure copper

A novel approach for predicting the intermetallic compound (IMC) formation during friction stir welding (FSW) of AA6061 to commercially pure copper has been developed, in addition their effect on mechanical properties. The temperature distribution aluminium weld nugget determined by a finite element model, use an Al–Cu phase diagram and elemental concentration have combined predict validate several IMCs present different zones weldment. results performing butt-welding these dissimilar metals using FSW process demonstrated that highest ultimate tensile strength 194.5 MPa was achieved at 1500 rev min−1 tool rotational speed, 100 mm traverse speed zero-tool offset.