Friction Stir Channeling Tool Design for Better Material Flow and Channel Strength

Abstract

This research investigates the impact of shoulder-workpiece separation on the friction stir channeling of copper, comparing two distinct tool designs. One design includes a clearance between the tool shoulder and workpiece; while, the other utilizes a grooved tool shoulder to eliminate this clearance. The findings reveal that direct contact between the tool shoulder and workpiece in the no-clearance design significantly affects the channels dimensions, microstructure, and mechanical properties. Notably, a distinct interface separating microstructural zones acts as a crack initiation site under tensile stress, leading to premature fractures of the channel roof. The results suggest that channels fabricated with shoulder-workpiece clearance improve tensile strength, offering a promising approach for manufacturing advanced heat sinks.

Sooraj Patel

Junior Research Fellow

Sooraj Patel is Junior Research Fellow in Advanced Materials Processing Research Group at Indian Institute of Technology Gandhinagar. He is working in the field of friction stir channeling of copper alloy. Recently, he has worked in the field of center-line segregation of twin roll cast aluminium alloy.