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Abstract
Friction stir welding parameters were developed for a 6 mm thick dissimilar butt joint made of mild steel and Ni based alloy 625. A composite W-Re/polycrystalline cubic born nitride tool was used to study the effect of tool offset (between 0 and 3·13 mm away from the alloy 625 plate) and rotational speed (between 250 and 350 rev min−1) on joint consolidation. When non-optimal parameters were used, macrovoids were observed at the advancing side and faying surface near the joint interface root. Defect free joints were obtained using 300 rev min−1, 100 mm min−1, tool offset of 1·63 mm, and axial force between 25 and 30 kN, under force controlled mode.
Acknowledgements
The authors gratefully acknowledge Petrobras for the financial support, the Brazilian Nanotechnology National Laboratory (LNNano-CNPEM) for the technical support and Russell Steel from MegaStir Technologies for fruitful discussions.