Abstract
The metal flow in friction stir welding (FSW) takes place by two modes - The first mode of metal transfer takes place by tool shoulder and the second mode by the tool pin. A small quantity of metal is transferred from the front side to rear side as layer one over the other for every rotation of the tool. The first mode offers compactness to the weld and is responsible for defect free weld formation. Remaining metal passes around the pin as a second mode of metal transfer. Recent advances in welding are focused on FSW of steels. In this study, the two modes of metal transfer phenomenon are analyzed to understand the formation of FSW of steels. The first mode of metal transfer increases the compactness of the weld and eliminates defects. An increase in the first mode of metal transfer improves the tensile properties. There exists a linear correlation between the percentage of first mode in the fractured surface and the ultimate tensile strength. Micro hardness measurement showed higher value at both stir zone and HAZ compared to base metal due to grain refinement. At 1400rpm tool rotation speed the tensile specimen is found to fail at the base material. Hence, maximum possible strength has been achieved.
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