Characterization of tool wear in similar and dissimilar joints of MS and SS using EAFSW

Abstract

Abstract Friction Stir Welding (FSW) faces many issues while joining high strength material. In this study an external secondary heat source from a DC source kept at 4 V supply has been used to in between the tool and the workpiece to give an external heat source to FSW and use the method as Electrically Assisted Friction Stir Welding (EAFSW) process. This study represents analysis of mechanical properties of Mild steel (MS) and Stainless-Steel (SS) joint, made by both FSW and EAFSW. An effect of the secondary heat source of electric energy on the mechanical property of the joint and to the tool wear while joining similar and dissimilar material of MS and SS has also been studied. The study represented the effect of the addition of a secondary heat source of an electric current heating to FSW and the impact of various process parameters like tool rpm and feed on the tool wear. The results have been shown to express an expected tool life of WC tool material for joining mild steel and stainless steel. Th experimentation has proved the suitability of Tungsten Carbide as tool material for joining high strength material such as MS and SS. It has also been observed that with suitable utilization of process parameters and secondary heat sources, the heat at the nugget zone increases causing better mixing of the nugget zone. Due to a generation of higher heat at the nugget zone, less tangential and radial load occurs at the tool pin resulting less tool wear and better tool life.