Abstract
The joining of aluminium (Al) and copper (Cu) is an essential spot weld for renewable energy applications due to its excellent thermal and electrical conductivity. It is challenging to produce a high-quality Al-Cu spot weld using traditional techniques and the durability of a weldment is also uncertain. A new welding technique that is effective and suitable for spot welding Cu and Al is friction-melt-bonding (FMB) spot welding. The process parameters employed during welding have a strong impact on the quality of a weld. The strategy for integrating the FMB process characteristics, such as tool rotational speed and dwell time, into a mathematical model that may be used for predicting the process parameters of dissimilar spot joints, was the focus of this study. The findings showed that the tensile shear fracture load (TSFL) was significantly influenced by the tool's rotational speed and dwell time. Optimization was carried out using the response surface methodology (RSM) to find the best FMB process parameters for making a dissimilar spot weld of AA 6061-Cu.