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By using fusion welding to weld AISI 304 austenitic stainless steel (ASS) and commercial copper, the creation of brittle intermetallic in the weld region that compromises the strength of the joints is the primary challenge. However, friction welding is a suitable method for joining these two materials because no obvious defects are produced at the joints. The joint strength is significantly influenced by the friction-welding-process variables including the pressure of friction, pressure of forging, time of friction, and time of forging. Throughout this study, a central composite factorial design-based empirical relationship-building effort was carried out to determine the tensile strengths of friction-welded AISI 304 austenitic stainless steels (ASS) and commercial copper alloys dissimilar joints from the process variables. The process conditions were optimized employing response surface methods in order to attain the joint’s optimum tensile strength. This research revealed that the greatest tensile strength of the joint created with the friction pressure of 60 MPa, forging pressure of 60 MPa, friction duration of 4 s, and forging time of 4 s, correspondingly, was 489 MPa. As a result, the intermetallic formation at the interface could be identified.

An investigation was carried out to quantify and characterize the corrosion behaviour of AZ31B magnesium alloy joints. Extruded Mg alloy plates of 6 mm thick of AZ31B grade were butt welded using a solid state, environmentally cleaner welding process, friction stir welding process. The weld specimens were underwent immersion, salt spray, pitting and galvanic corrosion tests in order to quantify and characterize the corrosion rates of the welds with the influence of different pH values, chloride ion concentration and the corrosion time. The corrosion rates, microstructure, scanning electron microscopy and X-ray diffraction analysis concludes the optimum parameter for the usage of the magnesium alloy welds for the best service applications. Keywords: Keywords: EDM, Alumina and Genetic Algorithm