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The dissimilar welding of titanium and copper by fusion welding is very difficult because the melting points of the materials are very highly different and strong brittle intermetallic compounds (IMCs) can be easily produced in welded zone and heat-affected zone, etc. Friction stir welding was employed as a type of solid-state welding for Ti/Cu dissimilar welding to obtain a sound welded zone and reduce the total process cost. This study investigated how the metal flow of the welded zone changes according to the variation in the rotational speed of the tool, from 450 rpm to 600 rpm. When the rotational speed was too high, the plastic flow of the softened material increased and intermetallic compounds such as TiCu, Ti2Cu3, and Ti2Cu, were generated in the Cu region of the welded zone. The microstructural evolution of AS (Advancing Side) and RS (Retreating Side) were investigated and the soundness of the welded zone and its mechanical properties were evaluated through the microstructural evolution. A high hardness value of 200 Hv or more was exhibited in some points, due to the formation of intermetallic compounds in the RS (Cu) region. Ti/Cu dissimilar friction stir welding at a welding speed of 50 mm/min and an appropriate rotation speed of 500 rpm showed a good welded zone and mechanical properties.

Effects of Rotation Speed on Microstructure and Mechanical Properties in Ti/Cu Dissimilar Friction Stir Welding