Abstract
Friction Stir Welding is a unique way of welding similar or dissimilar materials, utilizing the friction created between the spinning tool and workpiece. This work focus on improving the weld quality obtained from micro-FSW of dissimilar materials. The tool profile used is vital in generating the frictional heat, and its failure degrades the actual process. So, the need for selecting or designing a best tool for the process is important. Design methodology is used to make this process more efficient. Several design concepts have been utilized; including Mind Map, Morphological chart, and the best tool profile was assessed using a Pugh matrix. Finite Element Analysis (FEA) was carried out using different tool profile subjected to heat generation. Based on the temperature distribution and minimum deflection criteria, the best tool design is selected and compared with the tool profile obtained based on design methodology. The best conceivable concept has been the tool pin with a triangular profile. Based on the study High Carbon High Chromium tool steel is selected as tool material, considering the mechanical properties and cost of tooling.
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