Copper and aluminum materials are extensively used in different industries because of its great conductivities and corrosion resistant nature. It is important to join dissimilar materials such as copper and aluminum to permit maximum use of the special properties of both the materials. The joining of dissimilar materials is one of the most advance topic, researchers have found from last few years. Friction stir welding (FSW) technology is feasible to join dissimilar materials because of its solid state nature. Present article provides a comprehensive insight on dissimilar copper to aluminum materials joined by FSW technology. FSW parameters such as tool design, tool pin offset, rotational speed, welding speed, tool tilt angle and position of workpiece material in fixture for dissimilar Cu-Al system are summarised in the present review paper. Additionally, welding defects, microstructure and intermetallic compound generation for Cu-Al FSW system have been also discussed in this article. Furthermore, the new developments and future scope of dissimilar Cu-Al FSW system have been addressed.

In the present investigation, dissimilar materials such as electrolytic tough pitch copper and aluminum 6061-T651 were welded by friction stir welding technology. Effects of tool tilt angle on mechanical and metallurgical properties were studied experimentally for dissimilar materials system. In the present study, the tool tilt angle was varied from 0˚ to 4˚ with an interval of 1˚ while the other parameters such as rotational speed, welding speed, tool pin offset, workpiece material position were kept constant. Macrostructure analysis, tensile test, macro hardness measurement, scanning electron microscopy and energy dispersive x-ray spectrographic tests were performed to evaluate weld properties of dissimilar copper-aluminum joint. The results revealed that a defect free dissimilar copper-aluminum friction stir welding was achieved by tilt angles 2˚, 3˚ and 4˚.Maximum tensile strength was reported 117 MPa and macro hardness was reported 181 VH (in nugget zone) at the 4˚ tilt angle. Macro hardness was increased as tilt angle increases from 0˚ to 4˚. In addition to this, thermo-mechanically affected zone (at copper side) was found to be the weakest zone for dissimilar copper-aluminum friction stir welding system.

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