Friction stir cladding of copper on aluminium substrate

Thick cladding of copper is required for diverse applications, however, only a handful of processes can be used for bulk material cladding. This study has been undertaken to suggest a better alternative method for cladding thick layer of copper on aluminium substrate. Cladding of 3 mm thick layer of copper on 6 mm thick aluminium substrate has been successfully performed using friction stir welding process (FSW). Detailed microscopic study, XRD and microhardness evaluation of the samples proved the quality of clad layer. Interestingly even after three FSW passes no substrate material could reach near the top of clad layer. (C) 2021 CIRP.

Automated summary

This study successfully coated a 3 mm thick layer of copper on an aluminum substrate using friction stir welding (FSW), and the quality of the clad layer was confirmed through detailed microscopic examination, XRD, and microhardness evaluation. Interestingly, even after three FSW passes, the substrate material did not reach near the top of the clad layer.