Abstract:Components made by joining different materials are required in various engineering applications. Fabrication of such components is a challenging task due to the vast difference in mechanical, thermal and electrical properties of the materials being used. Friction stir welding (FSW) is capable of joining dissimilar materials such as aluminum (Al) and copper (Cu) and therefore researchers have used this novel process for dissimilar joining. Consequently, several works pertaining to dissimilar joining, specifically Al-Cu, are available in the literature but they are scattered in different sources, which makes the task of gathering information about dissimilar FSW of Al-Cu cumbersome. This work has been written with an aim to provide all pertinent information related to dissimilar FSW of Al-Cu at one place to ease the problems of researchers. It comprehensively covers and summarizes the topics such as the effect of tool design and geometry, FSW process parameters, FSW strategies on mechanical properties, microstructure and formation of defects during dissimilar FSW of Al-Cu. In addition, it also presents and discusses several variants of dissimilar FSW of Al-Cu. Finally, this work not only puts forth major findings of the previous researchers but also suggests future recommendations for dissimilar FSW of Al-Cu.

Key words: aluminium; copper; friction stir welding; intermetallic compounds; mechanical properties; weld nugget zone