Friction Stir Spot Welding Applied to Weld Dissimilar Metals of AA1100 Al-alloy and C11000 Copper

Friction stir spot welding is a non-conventional joining process that use for welding sheet metal and alloy as solid state process which can be used instead of electric resistance spot welding process. In this project, AA1100 Al-alloy and C11000 copper with 3 mm thickness have welded by friction stir spot welding with tapper cylinder tool made fro m high speed steel materials with pin diameter of 3 mm and shoulder diameter of 10 mm. Manual and automatic friction welding process have been applied in drilling machine with different rotational speed of 760, 1065, 1445 and 2000 mm. Heat generation, dwell time and applied load have been measured during the welding process as well as tensile test and tool depth penetration with surface quality were evaluated. The result shows that heat generated equal to 50 °C in case of automatic process and 210 °C in case of manual process. However, the dwell time that's required to complete the welding process in case of automatic process reduced to be 14% of the time that consume in the case of the manual welding process because applied load will be twice the time of manual applied load. Moreover, the maximum tensile strength of welded plates equal to 406 MPa at rotational speed of 1065 RPM.