Sharif University of Technology Scientia Iranica 1026-3098 32 2 2025 01 01 Impact of tool-related parameters during fabrication of dissimilar AISI 1010 –CDA 101 joints by FSW 23575 10.24200/sci.2024.60750.6974 EN K. Anil Basha Department of Mechanical Engineering, GRT Institute of Engineering and Technology, Tamil Nadu, India P. Sevvel Department of Mechanical Engineering, S.A.Engineering College (Autonomous), Tamil Nadu, India K. Giridharan Department of Mechanical Engineering, Easwari Engineering College (Autonomous), Tamil Nadu, India Journal Article 2022 07 09 An experimental endeavor was made to determine suitable tool geometry and ideal values of travel speed, tilt angle, pin offset distance for fabricating 5 mm thick dissimilar AISI 1010 and CDA 101 joints by Friction Stir Welding (FSW). Two differents sets of experiments were performed at constant 1200 rpm employing tools with distinct geometries and varying combinations of tool-related parameters. Reports affirmed the attainment of flawless joints during 2nd set of experimentation by employing a cylindrical shouldered tool (25 mm in diameter) having a cylindrically tapered pin at 1200 rpm, 40 mm/min travel speed, by tilting the tool at 2 °, with its pin being inserted a 1.5 mm offset distance towards<br />CDA 101 plate. Downward axial force of 7.214 kN was found to be ideal for joining these dissimilar metals and it was majorly influenced by the tool’s travel speed and pin’s offset distance. Presence of different sized Cu particles in AISI matrix, have led to the creation of brittle natured and large intermetallic amalgamations in nugget zone, thereby reducing the strength of fabricated defect-free weldment & leading to a diversified combination of brittle–ductile mode of fracture exhibiting a strength of 181 MPa. https://scientiairanica.sharif.edu/article_23575_618bb8caaeab7bc5ffc5d3892ea612e7.pdf