Dual-Rotation Speed Friction Stir Welding: Experimentation and Modeling

Implementing differential rotation speeds of pin and shoulder in the friction stir welding process is considered. Experimental investigations were carried out using a newly designed and fabricated apparatus for dual-rotation speed friction stir welding. Metallographic studies demonstrated that appropriate selection of separate pin and the shoulder rotation speeds not only results in defect-free joints, but also affects the weld zone by controlling the heat input delivered. An energy model for predicting maximum temperature was extended to the dual-rotation speed friction stir process. The model was verified using the previous experimental results reported in the literature.