Abstract— Friction stir welding is an emerging solid state welding method which is finding increasingly widespread industrial acceptance for joining similar and dissimilar materials. Aluminium to Copper bimetallic lap joints have got wide acceptance in the electrical and electronic industries. A three dimensional finite element model has been developed to study the thermo-mechanical history of the Al/Cu bimetallic lap joints. In this investigation, moving co-ordinate has been used to model the three dimensional heat transfer process because it reduce the difficulty of modeling the moving tool. Micro-hardness analysis has been carried out on friction stir welded joints.

Index Terms— Al/Cu bimetallic lap joints, Friction stir welding, Finite element method, Thermomechanical analysis, Micro-hardness

Cite: M Satya Narayana Gupta, B Balunaik, and K G K Murti, " Finite Element Modeling and Thermo-mechanical Analysis of Friction Stir Welded Al/Cu Bimetallic Lap Joints," International Journal of Mechanical Engineering and Robotics Research, Vol. 1, No. 2, pp. 165-173, July 2012.