In current research work, an attempt has been made to join dissimilar metals by employing friction stir welding (FSW), i.e., AA3003-H12 (aluminium alloy) and C12200-H01 (copper alloy). The experiments are designed as per full factorial design at different process parameters, namely tool pin profiles, rotational speed, welding speed, and shoulder diameter while the ultimate tensile strength (UTS), yield strength (YS), and percentage elongation (% E) are considered as a performance parameter. Moreover, a statistical tool, i.e., analysis of variance (ANOVA) is also utilized to check the adequacy of the results. It is observed that the higher UTS, % E and YS are obtained by employing a taper pin profile tool at a rotational speed of 1800 rpm, a welding speed of 16 mm/min, and a shoulder diameter of 22.5 mm. The ANOVA results showed that the rotational speed is the most significant factor for current research work. In addition, a scanning electron microscope is utilized for microstructural analysis of welded joints. It is witnessed that the minimum grain size, i.e., 4 microns, is obtained for highest strength specimen and the maximum grain size is obtained for the lowest strength specimen i.e., 31 microns. Besides this, the swirling of cu particle is also observed from advancing side (AS) to the retreating side (RS). Moreover, energy-dispersive X-ray spectroscopy (EDS) indicates the formation of intermetallic compounds i.e. Al₂Cu, Al₉Cu₄ at nugget zone (NZ). The hardness is found to be higher at NZ due to the presence of Al-Cu intermetallic.

在当前的研究工作中，已经尝试通过搅拌摩擦焊（FSW）即AA3003-H12（铝合金）和C12200-H01（铜合金）来连接异种金属。实验是根据全因子设计在不同工艺参数下进行的，这些工艺参数包括工具销轮廓，旋转速度，焊接速度和肩部直径，而极限抗拉强度（UTS），屈服强度（YS）和延伸百分率（％E）被视为性能参数。此外，还使用统计工具，即方差分析（ANOVA）来检查结果是否足够。可以看出，通过采用锥形销轮廓工具在1800 rpm的转速，16 mm / min的焊接速度和22.5 mm的肩部直径下获得更高的UTS，％E和YS。方差分析结果表明，转速是当前研究工作的最重要因素。另外，将扫描电子显微镜用于焊接接头的微观结构分析。可以看出，对于最高强度的样品，获得最小的晶粒尺寸，即4微米；对于强度最低的样品，获得最大的晶粒尺寸，即31微米。除此之外，还从前进侧（AS）到后退侧（RS）观察到cu粒子的回旋。此外，能量色散X射线光谱（EDS）表示金属间化合物即Al的形成 对于最高强度的样品，获得最大粒径，而对于最低强度的样品，获得最大粒径，即31微米。除此之外，还从前进侧（AS）到后退侧（RS）观察到cu粒子的回旋。此外，能量色散X射线光谱（EDS）表示金属间化合物即Al的形成 对于最高强度的样品，获得最大粒径，而对于最低强度的样品，获得最大粒径，即31微米。除此之外，还从前进侧（AS）到后退侧（RS）观察到cu粒子的回旋。此外，能量色散X射线光谱（EDS）表示金属间化合物即Al的形成熔核区（NZ）的₂ Cu，Al ₉ Cu ₄。由于存在铝-铜金属间化合物，因此发现在NZ处的硬度更高。