Optimization of Friction Welding Process Parameters for Weldment of Aluminium–Copper Electrical Connector

Friction welding of aluminium and copper has been widely used in electrical transmission in production of bimetallic (lug) or connectors. The use of dissimilar metal connector is to prevent high electrical losses due to contact resistance and mechanical contact between aluminium and copper which is not permanent in their application for the fact of environmental degradation. Galvanic corrosion between the two metals in mechanical contact is saviour and it is technically distractive; hence friction welding of the two metals solved the problem by introducing technically acceptable joint between the two metals. Mechanical strength of the connectors has been very important to withstand stress caused by heat and mechanical force. Electrical resistance behaviour has also been highly important. The aim of this research has to optimize process parameters that gave the best electrical and mechanical properties of the weldment. The selected materials and method are different and unique from any other studies. Optimization of welding parameter that gave two characteristics of their performances such as strength and electrical resistance when optimized successfully. Grey relational analysis, ANOVA and Taguchi method have been used for the optimization process. Vertical drilling machine was used for the friction welding process and the machine was 1.7 KW power with the rotational speed of 3060 RPM. The optimization of the process parameters of the friction welding, i.e. RPM, friction pressure and friction time was conducted. The obtained optimum setting for two performance output characteristics such as strength and electrical resistance was friction time at 20 seconds, friction pressure 117 (MPa) and 1050 (RPM). Furthermore, based on two performance studies, friction pressure has a basic parameter that determined the desired response.