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In friction stir welding, lesser tool life restricts the usage of non-circular pin in friction stir welding tool eventhough it delivers comparatively better weld joints than circular pin. Process peak temperature during the process affects the shear strength of the flowing material around the tool pin. Maintaining the process peak temperature as low as possible improves the properties in heat affected zone but on the other hand it increases the stress on the tool pin.Especially on the usage of non-circular pin, the pin surface experiences uneven stress distribution and causes premature tool failure. In this paper, optimum thermal environment through proper selection of process parameters and dwell period with respect to the pin geometry are analysed. A comparative analysis is also made to understand the impact of increase in flat surfaces in the pin surface on weld quality in the view of developing a suitable thermal environment that can improve tool life without compromising joint strength. Apart from this, optimum dwell period for the chosen tool pin geometry is analysed based on the empirical softening temperature of the material.

Experimental analysis on friction stir welding using flat-faced pins in AA2024-T3 plate