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A methodology incorporating friction stir processing (for plasticising) and friction stir welding (for joining components) was developed to fabricate T-shaped copper conductor rails. Experiments were undertaken on copper plate specimens (thickness 8-20 mm). Friction stir welding was conducted using conical tools made from HS 6-5-2 high-speed steel and a tungsten probe at a rotational speed of 355-560 rpm, travel speed of 71 mm/min and a tool tilt angle of 0 or 1.5 degrees. Both T-joints and butt joints were produced and specimens were characterised by microstructure observations and hardness measurements. Issues discussed include wormhole formation and welding-induced distortion.

10th International Symposium, 20-22 May 2014, Session 10B: High Temperature, Paper 01