Rotary friction welding of aluminum to copper using insert plate

In this study, a novel rotary friction welding method of copper (Cu) and aluminum (Al) using insert plate was investigated. In this method, a refractory metal plate was inserted between Cu and Al round bars, and the Cu bar was rotated under friction pressure. With the Cu bar rotating, the insert plate is pulled out instantaneously from the interface, and Cu and Al bars are welded under upset pressure. A friction welding equipment was designed and built for this purpose. Cu and Al bars were joined in this way. Tensile tests were applied to the joints. The tensile strength of the joint was 82 MPa. The micro photos of the joints were examined using an optical microscope. The results obtained showed that the welded zone had little grey layer and the bond strength of the joint was enhanced.