Abstract
Abstract The main aim of this study is to analyse the influence of tool plunging rate on tool wear and stir zone characteristics of DMR249A high strength low alloy (HSLA) steel joints developed using friction stir welding (FSW). The HSLA steel plates were welded at five levels of tool plunging rates varying from 2.0 mm min−1 to 3.0 mm min−1. The tool rotational speed of 600 rpm and welding speed of 30 mm min−1 were kept constant during welding. The wear of FSW tool was analysed by microscopic observations of tool condition after welding, stir zone characteristics, weight loss measurement and pin profile analysis. The characterization techniques of optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were employed to analyse the microstructural characteristics of stir zone of welded joints. Results disclosed that the severe degradation of FSW tool occurred due to the sudden dynamic impact load on tool pin while plunging and more diffusion of work piece material into the tool pin which leads to insufficient plasticized material flow. The tool plunging rate of 2.5 mm min−1 showed minimum tool wear and produced defect free sound joint.
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