Experimental and numerical analysis of friction stir welded dissimilar copper and bronze plates

Abstract

Friction Stir Welding (FSW) is a type of solid-state welding process that involves joining of metals without fusion or filler materials. The frictional heat is produced by a rapid rotating non-consumable high strength tool pin that extends from a cylindrical shoulder. In this paper 6mm, thick copper and bronze plates are friction stir welded at different tool rotational speeds of 800, 1000 and 1200 RPM, with a constant travel speed of 40 mm/min and an axial force of 10 kN. Tests like Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Microhardness is done to identify the metallography studies. The friction stir welding experiments are carried out with the transverse speed of 40 mm/min of the tool. Vickers hardness test, microstructure analysis is performed on the welded material. The ANSYS model analysis is done in FSW process and the various temperature distributions during different travel time values are evaluated. The findings from these investigations are presented and discussed.