ABSTRACT
Aluminum-Copper dissimilar joint has applications in the field of electrical as well as the automobile industry. Due to the difference in thermo-physical properties, Intermetallic Compound (IMC) formation takes place which is a major challenge. In the present study, aluminum alloy 1100 is weld-brazed to copper (Cu-DHP) using gas metal arc welding process. Aluminum alloy 4047 is used as a filler wire. Tin is the interlayers placed between the two metals. The effect of process parameters like mode of pulsing, copper pre-heating temperature, interlayer and wire-feed rate on joint properties has been examined and strength is obtained as the response. Taguchi method has been employed to optimize the weld brazing of aluminum to copper. The analysis of variants has been carried out and the impact of process parameters on responses has been evaluated. The mode of pulsing, wire-feed rate and welding speed affect the wetting characteristics and mechanical performance of the joint. The joint performance is evaluated using a lap-shear test. The Structure is characterized by Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) for chemical analysis.
