Evaluating Friction stir welding (FSW) as a novel thermomechanical technique for creating high strength copper composites

Friction Stir Welding (FSW) is a solid state process for joining metals without melting them completely. FSW uses a non-consumable rotating tool to heat and mechanically condition the target area, making it suitable for joining thermally conductive materials like copper. This research investigates the suitability of FSW for micro-forging and joining copper with dissimilar metals including tungsten and stainless steel. The thesis presents a comparative study of optimal conditions for friction stir forming of copper, and its application to create hybrid composites which exhibit valuable properties for applications in power and nuclear engineering. The thesis further establishes the effectiveness of friction stir forming techniques for repairing copper components. With use of state-of-the-art neutron based non-destructive techniques to evaluate the structural integrity of hybrid copper composites, this thesis contributes to the field of friction stir based techniques for joining dissimilar metals.