Abstract
Abstract Tool offset position is the key parameter to consider during the welding of dissimilar metals by friction stir welding technique. It helps to control the formation of brittle intermetallics and volume defects. Even tool offset position can leave defects at the interface when it exceeds a certain limits, and it has been reported as two-thirds of the bottom radius of the tool. In this work, the effect of the maximum tool deviation (complete offset) on intrinsic microstructure and fatigue life of AA 2024-copper weld was studied. For this, an experiment was carried out with complete tool offset position. The results highlighted that the stir zone was formed mainly by aluminum and the total volume of copper transferred into the stir zone was measured as 5.6 % of the total volume of the stir zone. This kind of structure gives excellent fatigue life to the weld compared to the regular microstructure formed during friction stir welding.
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