Influence of tool rotation and feed rate on the FSW process for copper and brass lap welding

• Grant number: 24/01036-3
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Start date: April 01, 2024
• End date: March 31, 2026
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Francisco Mateus Faria de Almeida Varasquim
• Grantee: Maike Rochel de Toledo
• Host Institution: Instituto Federal de Educação, Ciência e Tecnologia de São Paulo (IFSP). Campus Itapetininga. Itapetininga , SP, Brazil

Abstract

The Friction Stir Welding (FSW) process is a method that uses a rotating tool with a non-consumable pin to weld materials. This process allows the joining of similar or dissimilar materials. However, the combination of process parameters (rotation, feed rate, tool angle, and penetration) must be precise to generate a quality weld bead. In this project, the influence of tool rotation and feed rate on the FSW dissimilar welding process of overlapping copper and brass sheets is to be evaluated. The tools will be made of SAE 5160 steel with a conical pin. The tests will be performed on a 3-axis machining center, with rotation ranges between 800 and 1200 rpm and tool feed rates varying from 20 to 60 mm/min. The weld beads generated will first be visually evaluated. If approved, the same will be analyzed through macrography and microscopy (SEM with EDS and EBSD), X-ray diffraction (XRD), and the hardness profile will be plotted to compare the base material, the heat-affected zone (HAZ), and the welded region. The tool wear will also be evaluated by visual analysis and measurement of pin consumption.