ABSTRACT
Aluminum-copper dissimilar joints are used in electrical industry for cable lugs, joint casing etc. as well in Li-ion battery used in electrical vehicles. But it is quite difficult to weld dissimilar metals due to their difference in melting points. The effect of introduction of Zinc as interlayer in the welding characteristics is studied in our research project. For which 1mm thick aluminum alloys (A1100) sheet is jointed to 1mm thick copper (Cu-DHP) sheet using Gas Metal Arc Welding (MIG) process. The Aluminum sheet is placed over the copper sheet and arc is run along the edges of aluminum to form a joint. The process parameters like wire feed rate, inter layer, mode of pulsing, pre-heating, were chosen as parameters. Aluminum alloy 4047 was used as the filler wire and the specimen was tested for lap shear strength. SEM images were used to study the microstructure of each specimen and EDS spectrum was used for elemental analysis.
