Investigation of the joining of additively manufactured aluminum to copper by friction stir welding

Since aluminum and copper are utilized side by side in many important industries, joi-ning these metals is significant. It is considered that using these materials together by welding, copper can be effectively saved and lighter and more efficient systems can be produced. In this context, the feasibility of joining AlSi10Mg aluminum alloy, produced by additive manufacturing, to commercial pure copper using friction stir lap welding (FSLW) was investigated. It was aimed to reveal the effects of tool rotation and feed rate, which are the most important welding parameters in FSLW, on weld geometry, microstructure, mechanical properties, and intermetallic compounds formed in the weld zone. Tool rotation and feed rate speeds have been shown to have a significant effect on weld geometry and mechanical properties. The presence of defects such as hooks, voids, and intermetallic compounds was detected in the welds. Hook defect has emer-ged as the dominant factor determining the strength and fracture behavior of welds du-ring tensile testing. Based on the results obtained, it was concluded that it is possible to join aforementioned materials by the FSLW method.