Executive Summary : | Aluminium (Al) and copper (Cu) are widely used in industries due to their corrosion resistance and electrical conductivity. However, joining dissimilar materials presents a new challenge due to differences in their physical and chemical properties, leading to the formation of brittle intermetallic compounds at the joint interface. Friction stir welding (FsW) is a suitable process for joining these materials, but brittle intermetallic formation can be improved by optimizing process parameters. Researchers have recently reduced this problem by inserting intermediate interlayers at the joint interface, preventing brittle intermetallic compounds (IMCs) by reducing thermal expansion mismatch between base materials. This proposal aims to reduce brittle IMC formation and enhance joint strength by preventing direct contact between base materials by inserting third materials like zinc and silver as intermediate interlayers. The project aims to optimize process parameters to achieve an effective friction stir welded Al-Cu system with hybrid interlayers. The study will also analyze the role of interlayers in reducing brittle intermetallics and the microstructural investigation, mechanical, electrical, and corrosion characteristics of friction stir welded joints of 6101 aluminium alloy and C11000 copper alloy plates. |