Friction Stir Welding of Dissimilar Metals of Copper and Brass

Project Title

Friction Stir Welding of Dissimilar Metals of Copper and Brass

Project Area of Specialization Mechanical EngineeringProject Summary

Friction Stir Welding is a solid state welding process in which 2 metals are joined together before reaching their melting point. In this welding we are going to make a butt joint of copper and brass metal on a vertical CNC Milling machine. The metal sheet of 6mm thickness is cut through EDM Wire cut into a standered specimen according to ASTM and then these specimens are joined together by using a tool of high speed steel material. Tool consists of 3 parts including a holder, shoulder  and a pin. Pin, having different geometries, enters the material and rotates at a specific RPM and moves forward at a specific traverse speed in order to stir the material molecules from inside. The shoulder first half surface area remains in touch with the surface of one material and other half with the other material in order to create heat through friction. This heat helps plasticized material to join before their melting point. The tool is being hold by the milling machine using its holder part.

After joing the specimens we are going to perform tensile test on UTM, Vicker's hardness test and microstructural evaluation of the joint through scanning electron microscope. During the joining process thermal images are also taken using thermal image camera which shows the heat distribution in different areas throughout the joint.

Project Objectives

1) To successfully weld the joint by friction stir welding using CNC Milling machine.

2) To successfully perform Vicker's hardness test, tensile test on UTM and microstructural evaluation on SEM.

3) To compare our final results with the results of other researchers.

Project Implementation Method

Step 1: Literature review and manage their citation using Mendeley software.

Step 2: To purchase material of copper and brass and tests their composition.

Step 3: To cut the material in standard specimens using EDM wirecut.

Step 4: To purchase tool material of high speed steel and tests its compositon.

Step 5: To cut the tool in three different pin geometries as cylindrical, conical and square.

Step 6: To design nine experiments by taguchi's approach using minitab software taking three different values of three parameters including tool rotational speed, traverse speed and pin geometry.

Step 7: To perform welding process on CNC Milling machine.

Step 8: To observe heat distribution across different areas using thermal image camera.

Step 9: To perform hardness and tensile tests on respective machines.

Step 10: To study microstructural evaluation.

Step 11: To compare the results with other researches.

Benefits of the Project

1) Achieve a joint of higher strenght because material is not melted during welding.

2) Their is a research gap in FSW of copper and brass materials, so by applying different values of different variables we can achieve the results which no one has achieved before.

3) These materials are use mostly in automotive (radiator cores, tubes and tanks) and aerospace (aircraft bushings and bearings for landing gears, cargo doors, wheel and brake components) industries, shipbuilding (pumps, feed heaters and valves), stock for railways where joints need higher strengths. FSW is beneficial in these industries.

Technical Details of Final Deliverable

Vicker's hardness test, tensile test on UTM and microstructural evaluation on SEM.

material of copper and brass and tests their composition.

tool material of high speed steel and tests its compositon.

taguchi's approach using minitab software

thermal image

tensile test on UTM, Vicker's hardness test and microstructural evaluation of the joint through scanning electron microscope.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther IndustriesCore Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	11488
Brass material	Equipment	2	1400	2100
Copper material	Equipment	1	2200	2860
Tool material HSS H13	Equipment	1	1000	980
Tools material HSS M2	Equipment	1	2600	2548
SEM testing	Miscellaneous	3	1000	3000