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In this study, dissimilar CuNiCrSi and CuCrZr butt joints were friction stir welded at a constant welding speed of 150 mm/min, but at different rotational speeds of 800, 1100, 1400, 1700, and 2100 rpm. Sound joints were achieved at the rotational speeds of 1400 and 1700 rpm. It was found that the area of retreating material and grain size in the nugget zone increased with the increase of tool rotational speeds. The base metal on the CuNiCrSi side (CuNiCrSi-BM) contains a large density of Cr and δ-Ni2Si precipitates, and a great deal of Cr precipitates can be observed in the base metal on the CuCrZr side (CuCrZr-BM). All these precipitates are completely dissolved into the matrix in both the nugget zone on the CuCrZr side (CuCrZr-NZ) and the nugget zone on the CuNiCrSi side (CuNiCrSi-NZ). The precipitation strengthening plays a dominant role in the base metals, but the grain boundary strengthening is more effective in improving the mechanical properties in the nugget zone. Both the hardness and tensile strength decrease sharply from the base metal to the nugget zone due to the dissolution of precipitates. Mechanical properties such as microhardness and tensile strength in the nugget zone decrease with the increase of rotational speeds because the grain size is larger at a higher rotational speed.

Effect of Tool Rotational Speeds on the Microstructure and Mechanical Properties of a Dissimilar Friction-Stir-Welded CuCrZr/CuNiCrSi Butt Joint