JME_V1_N2_RP1 J. Kandasamy M. Manzoor Hussain S. Rajesham Journal on Mechanical Engineering 2249 - 0744 1 2 9 16 FSW, AA7075, Copper Coating, IMC, Mechanical Properties, Microstructures, Fractography Friction Stir Welding (FSW) is an innovative and promising solid state joining process invented by The Welding Institute (TWI). FSW is considered to be one of the most significant developments in metal joining technology over the last two decades. Experiments were conducted on 6 mm thick AA7075 aluminum plates with copper coating on the faying surfaces. The plates were joined by friction stir welding under optimized conditions and the weldments were investigated for mechanical and metallurgical properties to identify the influence of the intermetallic compound (IMC) formed during the process. Results show substantial improvement in mechanical and metallurgical properties with copper coated weldments over conventional weldments. Crack initiation and specimen fracture were observed in the thermo mechanically affected zone of the weldments with superior tensile strength, finely elongated grains and reduced defects. February - April 2011 Copyright © 2011 i-manager publications. All rights reserved. i-manager Publications http://www.imanagerpublications.com/Article.aspx?ArticleId=1402