Aluminium (Al) and copper (Cu) are widely employed in the industry due to their significant corrosion resistance and electrical conductive properties. The simultaneous requirement of different special properties has increased the trend of joining of Al and Cu. The joining of dissimilar materials has arisen as a new challenge in the research field in the past decade. Friction stir welding (FSW) is a very worthy process to join metals that aren't the same. This article delves into the intricacies of FSW to join compatible metals such as Al and Cu. The various parameters of FSW, namely tool design, tool pin offset, rotation speed, welding speed, tilt angle, and different types of welding joints, are highlighted in this article. It also goes through the different types of defects, microstructures, and intermetallic compounds (IMCs) that are formed during Al-Cu FSW. The electrical behavior and corrosion behavior of the weld zone in Al-Cu FSWed joints were also reviewed. Role of interlayer in some emphasis was also given to form effective joints.
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