Optimization Of Friction Welding Parameters For Weldment Of Aluminium-Copper Electrical Connector

Abstract

Friction Welding Of Aluminium And Copper Has Wide Application In Electrical Transmission In Production Of Bimetallic (Lug) Or Connectors. The use Of Dissimilar Metal Connector Is To Prevent High Electrical Loses Due To Contact Resistance, And Mechanical Contact Between Aluminium And Copper Is Not Permanent In Their Application Due To Environmental Degradation Due To Dissimilar Metal Contact. Problem Such As Galvaniccorrosion Between Two Metals In Mechanical Contact Is Saviour And It Is Technically Distractive In Application Of Connectors In Electrolytic Or Humid Environments; Hence Fiction Welding Of The Two Metals Solves The Problem By Introducing Technically Acceptable Joint Between The Two Metals By Eliminating Occurrence Of Electrolytic Action Between Dissimilar Metal Contacts. Tensile Strength Of The Connectors Is Very Important To Withstand Stress Caused By temperature And Heat And Mechanical Force In Application. Electrical Resistance Behaviour Is Also Highly Important. Friction Welding Process Is Generally Used For Welding Dissimilar Metals Such As Aluminium And Copper And Process Parameters Are Significant Effect On The Forth Mentioned Tensile Strength And Electrical Resistance Properties Of The Connectors. Optimization Of Process Parameters Of Friction Welding Process Is Needed To Obtain Desired Response As Mentioned Above. Therefore The Aim Of This Research Is To Optimize Process Parameters That Give Best Electrical Resistance And Tensile Strength Properties Of The Weldment. Optimization Of Welding Parameter That Gives Two Performances Characteristics Such As Tensile Strength And Electrical Resistance Are Successfully Optimized. In Optimization Processgray Relational Analysis, Anova And Taquchi Method Are Used. Vertical Drilling Machine Is Used For Friction Welding Process And The Machine Is 1.7 Kw Power And Rotational Speed Of 3060 Rpm. The Optimization Of The Process Parameters Of The Friction Welding I.E. Rpm, Friction Pressure, And Friction Time Is Conducted. The Obtained Optimum Setting For Two Performance Output Characteristics Such As Strength And Electrical Resistance Is: friction Time At 20 (Second Maximum), Friction Pressure 117 (Mpa-Maximum) And Speed (1050 Rpm-Minimum).Furthermore Based On Two Performance Study Friction Pressure Is Basic Parameter That Determines The Desired Responses.