Abstract: Friction Stir Welding (FSW) was invented by Wayne Thomas at TWI (The Welding Institute), and the first patent applications were filed in the UK in December 1991. Initially, the process was regarded as a “laboratory” curiosity, but it soon became clear that FSW offers numerous benefits in the fabrication of Aluminium products. Friction Stir Welding is a solid-state process, which means that the objects are joined without reaching the melting point. This joining technique is energy efficient, environment friendly, and versatile. Friction stir welding has been proven to be an effective process for welding aluminium, brass, copper, and other low-melting materials. In FSW parameters play an important role like tool design and material, tool rotational speed, welding speed, and axial force.
In our project, we have used Aluminium material of 2025 and 7075 series with three different shaped tools and three different speeds, and three different feed rates.

The reason we choose aluminium for welding is because of its corrosion resistance and strength. Its weight advantage can also be used in the transport industry such as building Ships. Welding of these two aluminium materials can result in drastic improvement in strength and corrosion resistance. They can be also used in cold temperature applications, such as cryogenics and liquid natural gas transportation.

After welding, we sent the welded materials to go through some testing like Hardness Test, Tensile Test to check the properties like strength, ductility, resistance to corrosion, and others.

| DOI: 10.17148/IARJSET.2021.8327