Friction stir welding (FSW) is a relatively new solid-state joining process. This
joining technique is energy efficient. In particular, it can be used to join highstrength
aerospace aluminum alloys and other metallic alloys that are hard to weld
by conventional fusion welding. In this paper the investigation is made on friction
stir welding process for joining of copper alloy. Friction stir welding experiments
was performed using different pins (pin with straight boundary and pin with curved
boundary). Welding joints efficiencies were found for each set. Mechanical and
microstructural analysis has been performed experimentally on the welding zone.
Non- linear numerical models was built in ANSYS software to simulate the
thermal history of a workpiece undergoing friction stir welding by a moving
heating source. An accurate prediction of temperature fields is evident. Exclusive
result for effect of rotating a friction stir tools with respect to boundary conditions
on stress-strain curves is presented. The results shown that the friction stir welding
with pin of curved boundary is more efficient than that of straight boundary