Friction stir cladding of copper on aluminium substrate

Abstract Thick cladding of copper is required for diverse applications, however, only a handful of processes can be used for bulk material cladding. This study has been undertaken to suggest a better alternative method for cladding thick layer of copper on aluminium substrate. Cladding of 3 mm thick layer of copper on 6 mm thick aluminium substrate has been successfully performed using friction stir welding process (FSW). Detailed microscopic study, XRD and microhardness evaluation of the samples proved the quality of clad layer. Interestingly even after three FSW passes no substrate material could reach near the top of clad layer.