The Compatibility Analysis of Aluminum and Copper in the Rotary Friction Welding Process and Influence of the Friction Time on Joint Plastic Deformation

The principles of the friction welding (FW) process of the two different non-ferrous metals, aluminum and copper, are presented in this paper. Considering that the bimetallic Al-Cu joints find applications in electrical engineering, as well as in other industrial fields, the basic characteristics and compatibility of these metals are discussed, along with the influence of various parameters on the properties of their friction welded joint. The experimental study involved determining and analyzing the effects of process parameters on the occurrence, shape, and level of plastic deformation resulting from changes in the physical model during the rotational friction welding process (RFW). The specificity of the joining process is in the occurrence of various phenomena in the weld zone, which are significantly affecting the physical, structural, and mechanical properties of the base materials, thus influencing the joint quality. The friction welding process itself is complex, and the task is further complicated by the use of different base materials.