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Friction stir welding (FSW) is extensively used due to its low processing temperature, cost, and fast operation. The objective of this is research is to determine the optimum rotational and welding speed for welding of Al/Cu butt joint by FSW. FSW is used to produce a butt joint of pure aluminum with pure copper under two conditions; as received, i.e., not annealed, and as annealed. FSW is examined under three different rotational speeds: 910 rpm, 1280 rpm, and 1700 rpm, and each rotational speed is examined at three different welding speeds 16 mm/min, 29 mm/min, and 44 mm/min. The axial and longitudinal welding force components are measured during the welding process. Tensile and hardness tests were done to evaluate the mechanical properties, and the microstructural properties were also examined by XRD, SEM, and an optical microscope. The results showed that the welding force increased and the axial force decreased as the rotational speed increased and the welding speed decreased. Voids, tunnels, and cavities are noticed in case of a low rotational speed and a high welding speed; however, almost defect-free structure obtained at the highest rotational speed examined, i.e., 1700 rpm and the lowest welding speed of 16 mm/min, in case of Al and annealed Cu joint, but in case of non-annealed copper, it was different. It can be concluded that there is an optimal combination between the rotational speed and the welding speed in order to obtain the optimum mechanical and microstructural properties of the Al–Cu-welded joints, and that speed is a function of the material conditions. [ABSTRACT FROM AUTHOR]

Welding parameters like welding speed, rotation speed, plunge depth, shoulder diameter etc., influence the weld zone properties, microstructure of friction stir welds, and forming behavior of welded sheets in a synergistic fashion. The main aims of the present work are to (1) analyze the effect of welding speed, rotation speed, plunge depth, and shoulder diameter on the formation of internal defects during friction stir welding (FSW), (2) study the effect on axial force and torque during welding, (c) optimize the welding parameters for producing internal defect-free welds, and (d) propose and validate a simple criterion to identify defect-free weld formation. The base material used for FSW throughout the work is Al 6061T6 having a thickness value of 2.1 mm. Only butt welding of sheets is aimed in the present work. It is observed from the present analysis that higher welding speed, higher rotation speed, and higher plunge depth are preferred for producing a weld without internal defects. All the shoulder diameters used for FSW in the present work produced defect-free welds. The axial force and torque are not constant and a large variation is seen with respect to FSW parameters that produced defective welds. In the case of defect-free weld formation, the axial force and torque are relatively constant. A simple criterion, (∂ τ/∂ p) > (∂ τ/∂ p) and (∂F/∂ p) > (∂F/∂ p), is proposed with this observation for identifying the onset of defect-free weld formation. Here F is axial force, τ is torque, and p is welding speed or tool rotation speed or plunge depth. The same criterion is validated with respect to Al 5 xxx base material. Even in this case, the axial force and torque remained constant while producing defect-free welds. [ABSTRACT FROM AUTHOR]