Friction stir welding is a solid-state welding procedure in which a spinning tool rotates along with the

joint interface, creating heat and recirculating plasticized material along the tool surface. This plasticized
material is extruded by the rotational and traverse movements of the tool pin, resulting in the formation
of the so-called stir zone. The creation of the stir zone is influenced by the material flow behaviour
caused by the spinning tool.

Surface fractures, porosity solidification, and liquification are all frequent shortcomings of traditional
welding. Conventional welding also has an impact on the environment due to the harmful fumes and
gases released during the welding process. FSW resolves all welding-related issues. FSW provides alot of
advantages, including low thermal diffusivity, excellent mechanical qualities, little deformation, and no
fracture development.

Aluminium and magnesium alloys, as well as copper, steel, composites, and dissimilar materials, are
currently welded using the FSW technique. FSW welding of aluminium alloys, particularly heat treatable
wrought aluminium alloys such as, generate a higher-quality product than other fusion welding
processes such as gas metal arc welding.

The strength of a weld can be measured by calculating indicators such as shear strength, yield strength
and tensile strength. The tensile strength is the maximum amount of stress that a body can endure
before breaking or failing. On the other hand, the shear load is the force that acts in a parallel direction
to the planar cross-section or the surface or a body. Moreover, the yield strength is the stress whereby a
certain amount of irreversible deformation occurs on a body.

It is essential to study the relevant process parameters of the friction stir welding process and their
influence on the indicators of weld strength. Accordingly, by establishing the impact of the process
parameters on the indicators of strength, it is possible to perform, the friction stirs welding process of an
Aluminum-copper joint, under the best circumstances for optimal strength of the weld.

Input parameters

Tool transverse and rotational speed

In frictional stir welding the tool transverse speed in mm/min, and rotational speed in revolution per
minute(rpm). The transverse speed occurs along the line of the joint while rotation occurs in an
anticlockwise or clockwise manner. The rotary and translatory motion generate heat that softens
plasticized material, thus producing a seamless and solid-state joint. The production of heat mainly
occurs at the pin contact surface and the shoulder contact surface. The welding speed is a function of
joint type, penetration depth rotational speed and alloy type.

Plunge depth and tool tilt

Along with tool rotation speed and traverse speed, further critical process parameters include tool tilt
relative to the workpiece surface and plunge depth. A sufficient spindle tilt toward the trailing direction
guarantees that the shoulder securely grips the stirred material via the threaded pin and efficiently
moves material from the front to the back of the pin. Generally, the tool has a slight tilt angle and as it is
placed into the sheets, the blank material undergoes a local rearward extrusion process up to the tool
shoulder. Additionally, the plunge depth of the pin into the workpieces (also known as target depth) is
critical for making strong welds with smooth tool shoulders.
Tool design

The tool design influences the power needed, plastic flow, heat generation and the welded joint
uniformity. The key parameters in terms of tool design include shoulder size, probe shape and probe
length. These parameters affect the flow of plastic material and the amount of heat generated. The tool
consists of a shoulder and a pin. The profile of the pin influences the flow of material and the welding
speed of the process. Furthermore, the shoulder generates much of the heat in the process and
prevents the escape of plasticized material from the workpiece. The commonly used pin profiles include
the square, triangular, cylindrical threaded, straight cylindrical and tapered cylindrical pins.

Axial force

The downward force at which the tool contacts the workpiece influences the frictional conditions that
produce heat. It also works with the tool pin motion to propel the material after it undergoes plastic
deformation. Therefore, it contributes to material extrusion.

Design of the experiment

The full factorial experimental design method will be applied to develop a design matrix consisting of
the process parameters, and the number of experimental runs required. The full factorial experimental
method will be applied to design experiments that would determine the interactive effects of the input
parameters on the output parameters including ultimate tensile strength and yield strength. The
experiments will then be conducted according to the design matrix.

After the specimen are welded according to different settings of the input parameters, the various
tensile test specimen will be prepared. Next, the specimen will be tested for properties including yield
strength and the ultimate tensile strength. Finally, the results from the tests should be tabulated
accordingly.

Development of the numerical model

Through response surface analysis, numerical models will be generated, with the aid of the experimental
data. Accordingly, the yield strength and ultimate tensile strength will be functions of the input
parameters. Therefore, the output parameters will serve as the responses. The method will produce
regression models, which could be used to predict the effects of various input parameters on the
mechanical properties of the welded Aluminum and copper joints. Consequently, these graphs will be
used to highlight the best settings for the optimal FSW welding of AL-Cu.

Checking the validity of the regression model

A variety of methods can be applied to check the adequacy of a regression model. The methods include
the coefficient of determination, the analysis of variance method, and applying scatter diagrams. The
first two methods will give a rate of the model using a percentage, with higher percentages indicating
the level of confidence in the model. On the other hand, the scatter diagram rates the method according
to the proximity of observed and predicted response values to a 45-degree line.

Confirmation experiments
Confirmation experiments will be conducted to verify the regression models. Accordingly, predicted
outputs will be compared to actual outputs. Consequently, the percentage error will be scrutinized to
determine the effectiveness of the method.