Mechanical Engineering for Society and Industry

Articles

Effect of forging pressure and rotational speed on the quality of rotary friction welding of Al 6063 and copper joints

Yeni Muriani Zulaida , Muhammad Anis , Mahfudz Al Huda , Kirman , Hermawan Agus Suhartono

Published
February 5, 2026

Vol. 6 No. 1 (2026)
Pages 9-20

DOI

Open Access
Share

Abstract

This study investigates the effect of forging/upset pressure and high rotational speed on the quality of dissimilar metal joints between aluminum 6063 (Al6063) and copper (Cu). The method uses solid-state rotary friction welding (RFW) method. Joining dissimilar metals poses challenges due to significant differences in thermal conductivity, melting point, and mechanical properties. At high rotational speeds, the increased heating rate and higher frictional pressure result in greater deformation of the aluminum component. A novel aspect of this research lies in its systematic evaluation of the combined effects of forging pressure and rotational speed in an area that has received limited attention in prior RFW studies. Despite not achieving full joint efficiency, the results demonstrate that increasing forging pressure significantly enhanced joint strength up to an optimum level. Consequently, higher rotational speeds led to larger and more irregular flash due to rapid heat generation. However, a well-balanced combination between pressure and speed produced stronger joints with less flash. Excessive pressure was found to widen flash formation, while the heat generation from high rotational speeds diminished after material deformation. The RFW process in this study reached temperatures approaching 300°C; a very few intermetallic phases were detected at the Al/Cu interface. These findings contribute valuable insights into improving the weldability and mechanical performance of dissimilar Al-Cu through parameter optimization in RFW parameters.

Keywords

Rotary friction welding; Dissimilar metal welding; Al 6063; Forging pressure; Rotational speed

References

  1. [1] M. Sahin, “Joining of aluminium and copper materials with friction welding,” The International Journal of Advanced Manufacturing Technology, vol. 49, no. 5–8, pp. 527–534, Jul. 2010, doi: 10.1007/s00170-009-2443-7.
  2. [2] ASM Metal Handbook Vol.2, Properties and Selection : Nonferrous Alloys and Special-Purpose Material, vol. 2. 1992.
  3. [3] F. O. Edoziuno, C. C. Nwaeju, A. A. Adediran, B. U. Odoni, and V. R. Arun Prakash, “Mechanical and microstructural characteristics of Aluminium 6063 Alloy/Palm Kernel shell composites for lightweight applications,” Scientific African, vol. 12, p. e00781, Jul. 2021, doi: 10.1016/j.sciaf.2021.e00781.
  4. [4] S. N. Mohtar, N. Jamal, and M. Sulaiman, “Analysis of all aluminum conductor (AAC) and all aluminum alloy conductor (AAAC),” in 2004 IEEE Region 10 Conference TENCON 2004., IEEE, 2004, pp. 409-412 Vol. 3. doi: 10.1109/TENCON.2004.1414794.
  5. [5] P. Kah and M. S. Jukka Martikainen, “Trends in joining dissimilar metals by welding,” Applied Mechanics and Materials, vol. 440, no. 2014, pp. 269–276, 2013, doi: 10.4028/www.scientific.net/AMM.440.269.
  6. [6] G. B. Sathishkumar et al., “Friction welding of similar and dissimilar materials: A review,” Materials Today: Proceedings, no. xxxx, 2021, doi: 10.1016/j.matpr.2021.03.089.
  7. [7] M. Aritoshi and K. Okita, “Friction welding of dissimilar metals,” Welding International, vol. 17, no. 4, pp. 271–275, Jan. 2003, doi: 10.1533/wint.2003.3112.
  8. [8] J. P. Bergmann, F. Petzoldt, R. Schürer, and S. Schneider, “Solid-state welding of aluminum to copper - Case studies,” Welding in the World, vol. 57, no. 4, pp. 541–550, 2013, doi: 10.1007/s40194-013-0049-z.
  9. [9] M. Uzkut, B. Ünlü, S. Yilmaz, and M. Akdağ, “Friction Welding And Its Applications In Today’s World,” Sarajevo: International Symposium on Sustainable Development, pp. 710–724, 2010.
  10. [10] E. oualid Bouarroudj, S. Chikh, S. Abdi, and D. Miroud, “Thermal analysis during a rotational friction welding,” Applied Thermal Engineering, vol. 110, pp. 1543–1553, 2017, doi: 10.1016/j.applthermaleng.2016.09.067.
  11. [11] M. Maalekian, “Friction welding - Critical assessment of literature,” Science and Technology of Welding and Joining, vol. 12, no. 8, pp. 738–759, 2007, doi: 10.1179/174329307X249333.
  12. [12] R. Ramesh Kumar et al., “Experimental and analytical investigation on friction welding dissimilar joints for aerospace applications,” Ain Shams Engineering Journal, vol. 14, no. 2, p. 101853, 2023, doi: 10.1016/j.asej.2022.101853.
  13. [13] E. T. Akinlabi and R. M. Mahamood, Solid-State Welding: Friction and Friction Stir Welding Processes. in Mechanical Engineering Series. Cham: Springer International Publishing, 2020. doi: 10.1007/978-3-030-37015-2.
  14. [14] K. Faes, A. Dhooge, P. De Baets, E. Van Der Donckt, and W. De Waele, “Parameter optimisation for automatic pipeline girth welding using a new friction welding method,” Materials and Design, vol. 30, no. 3, pp. 581–589, 2009, doi: 10.1016/j.matdes.2008.05.073.
  15. [15] M. Kimura, I. Yuusuke, M. Kusaka, and K. Kaizu, “Effects of friction welding conditions on tensile strength of friction welded joint between 5052 Al alloy and pure copper,” Mechanical Engineering Journal, vol. 5, no. 2, pp. 17-00398-17–00398, 2018, doi: 10.1299/mej.17-00398.
  16. [16] M. Kimura, Y. Inui, M. Kusaka, K. Kaizu, and A. Fuji, “Joining phenomena and tensile strength of friction welded joint between pure aluminum and pure copper,” Mechanical Engineering Journal, vol. 2, no. 1, pp. 14-00328-14–00328, 2015, doi: 10.1299/mej.14-00328.
  17. [17] S. Senkathir and V. B. Siddharth, “Friction welding of dissimilar metals (aluminium AL 6061 T6 and stainless steel AISI 304),” IOP Conference Series: Materials Science and Engineering, vol. 912, no. 3, pp. 1–10, 2020, doi: 10.1088/1757-899X/912/3/032043.
  18. [18] M. Aritoshi, K. Okita, T. Enjo, K. Ikeuchi, and F. Matsuda, “Friction welding of oxygen free copper to pure aluminium,” Welding International, vol. 6, no. 11, pp. 853–859, Jan. 1992, doi: 10.1080/09507119209548302.
  19. [19] G. Wang, J. Li, W. Wang, J. Xiong, and F. Zhang, “Study on the effect of energy-input on the joint mechanical properties of rotary friction-welding,” Metals, vol. 8, no. 11, 2018, doi: 10.3390/met8110908.
  20. [20] V. Milašinović et al., “Continuous Drive Friction Welded Al/Cu Joints Produced Using Short Welding Time, Elevated Rotational Speed, and High Welding Pressures,” Materials, vol. 17, no. 13, p. 3284, Jul. 2024, doi: 10.3390/ma17133284.
  21. [21] E. P. Alves, F. P. Neto, C. Y. An, and E. C. da Silva, “Experimental determination of temperature during rotary friction welding of AA1050 aluminum with AISI 304 stainless steel,” Journal of Aerospace Technology and Management, vol. 4, no. 1, pp. 61–68, 2012, doi: 10.5028/jatm.2012.04013211.
  22. [22] A. Sasmito, M. N. Ilman, P. T. Iswanto, and R. Muslih, “Effect of Rotational Speed on Static and Fatigue Properties of Rotary Friction Welded Dissimilar AA7075/AA5083 Aluminium Alloy Joints,” Metals, vol. 12, no. 1, 2022, doi: 10.3390/met12010099.
  23. [23] Xun Li, L. Jinglong, J. Feng, X. Jiangtao, and Z. Fusheng, “Effect of rotation speed on friction behavior of rotary friction welding of AA6061-T6 aluminum alloy,” Welding in the World, vol. 62, no. 5, pp. 923–930, 2018, doi: 10.1007/s40194-018-0601-y.
  24. [24] T. Sawai, K. Ogawa, H. Yamaguchi, H. Ochi, Y. Yamamoto, and Y. Suga, “Evaluation of joint strength of friction welded carbon steel by heat input,” Welding International, vol. 16, no. 6, pp. 432–441, 2002, doi: 10.1080/09507110209549556.
  25. [25] K. Katoh and H. Tokisue, “Friction welding of aluminium to copper,” Welding International, vol. 20, no. 7, pp. 525–531, 2010, doi: 10.1533/wint.2006.3596.
  26. [26] N. Ratković et al., “Experimental and Numerical Analysis of Rotary Friction Welding for Al-Cu Joints: Effects of Friction Time on Plastic Deformation and Joint Integrity,” Materials, vol. 18, no. 9, 2025, doi: 10.3390/ma18091932.
  27. [27] L. Sauter, “Journal of Advanced Joining Processes Continuous drive friction welding of commercial pure aluminum to copper : Metallographic and mechanical characterization of various cross-sections,” Journal of Advanced Joining Processes, vol. 12, no. June, p. 100342, 2025, doi: 10.1016/j.jajp.2025.100342.
  28. [28] F. Cao, P. Zhang, J. Zou, and T. Wang, “The formation and growth of intermetallic compounds during interdiffusion of Al/Cu bimetals,” Materials Research Express, vol. 9, no. 5, 2022, doi: 10.1088/2053-1591/ac69b4.
  29. [29] Y. Wei, J. Li, J. Xiong, and F. Zhang, “Investigation of interdiffusion and intermetallic compounds in Al–Cu joint produced by continuous drive friction welding,” Engineering Science and Technology, an International Journal, vol. 19, no. 1, pp. 90–95, Mar. 2016, doi: 10.1016/j.jestch.2015.05.009.
  30. [30] W. Li, Q. Wen, X. Yang, Y. Wang, D. Gao, and W. Wang, “Interface microstructure evolution and mechanical properties of Al/Cu bimetallic tubes fabricated by a novel friction-based welding technology,” Materials and Design, vol. 134, pp. 383–393, 2017, doi: 10.1016/j.matdes.2017.08.065.
  31. [31] W. B. Lee, K. S. Bang, and S. B. Jung, “Effects of intermetallic compound on the electrical and mechanical properties of friction welded Cu/Al bimetallic joints during annealing,” Journal of Alloys and Compounds, vol. 390, no. 1–2, pp. 212–219, 2005, doi: 10.1016/j.jallcom.2004.07.057.
  32. [32] W. S. Ebhota and T.-C. Jen, “Intermetallics Formation and Their Effect on Mechanical Properties of Al-Si-X Alloys,” Intermetallic Compounds - Formation and Applications, 2018, doi: 10.5772/intechopen.73188.
  33. [33] Mohammed Asif and Shri, “The impact of heat input on the strength, toughness, microhardness, microstructure and corrosion aspects of friction welded duplex stainless steel joints,” Journal of Manufacturing Processes, vol. 18, pp. 92–106, 2015, doi: 10.1016/j.jmapro.2015.01.004.
  34. [34] H. Ochi, K. Ogawa, Y. Yamamoto, G. Kawai, and T. Sawai, “The formation of intermetallic compounds in aluminium alloy to copper friction-welded joints and their effect on joint efficiency,” Welding International, vol. 18, no. 7, pp. 516–523, 2004, doi: 10.1533/wint.2004.3282.
Article Metrics
84
Views
62
Downloads

SCITE

DIMENSIONS

Publication Information
Published February 5, 2026
Section Articles
Copyright Copyright (c) 2026 Yeni Muriani Zulaida, Muhammad Anis, Mahfudz Al Huda, Kirman Kirman, Hermawan Agus Suhartono
Keywords
  • Rotary friction welding
  • Dissimilar metal welding
  • Al 6063
  • Forging pressure
  • Rotational speed