In systems transporting fluids like petrol, water, or any fluids. Copper and brass pipes are used because of the capability to resist corrosion. The copper alloys can be welded by several methods like arc, resistance, friction welding, and gas methods and they can be readily soldered and brazed. In the present study, mechanical properties and finite element modeling evaluation for friction stir welding of two dissimilar pipes (C12200 copper alloy pipe with C36000 copper alloy pipe). During this study six parameters were used where rotation speed of (775,1000,1300 and1525rpm), welding speed of 1.7 mm/min, axial force of 8.5KN, with a CW direction of rotation, and zero degree of tilt angle, using a threaded cone geometry of the tool. The results showed that the best weld quality was in case when the speed of rotation was 1525 rpm.

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The friction stir welding is used for joining non-ferrous and ferrous materials whether tube-shaped sections or flat plates in several manufacturing applications like aerospace applications, transport land applications, and shipbuilding applications. This study is focused on friction stir welding joining for similar and dissimilar pipes as (AISI 316 Austenitic Stainless steel with API 5L carbon steels, 6063 aluminum alloy with API 5L carbon steels, 6063 aluminum alloy with C36000, 6063 aluminum alloy with C12200, 6063 aluminum alloy with 6082 aluminum alloy, AL 6063 alloy with AL 7022 alloy, 7022 aluminum alloy with C12200, 7022 aluminum alloy with C36000 and C36000 with C12200). The study was conduct for these joints to evaluate the mechanical properties by tensile test, visual inspection, and Microhardness test. In friction stir welding of these alloy systems, six welding parameters were used, rotation speed of (775, 1000, 1300 and 1525 rpm), welding speed of 1.7mm/min, axial force of 8.5KN, with a clockwise direction of rotation, and zero degree of tilt angle, using a tool with a threaded cone geometry pin. The results show that for (AL6063 with AL6082 weld joint cases the best case was case 19, AL6063 with AL7022 weld joint cases showed that the best case was case 21 and C36000 high-leaded brass with C12200 copper alloy showed that the best case was case 36).

The Finite Element Modeling has been achieved for two dissimilar pipes welded by friction stir welding for given operating conditions and cases. Moreover, this analysis has been carried out to find the effect of hydrostatic pressure test on the welding area of the pipe by ANSYS Workbench software. In this study dissimilar materials of different pipes were used for FSW, which they were joined as 6063 aluminum alloy pipe with 6082 aluminum alloy pipe and C36000 high-leaded brass pipe with C12200 copper alloy pipe. In this study six parameters were used and with those parameters, eight (8) cases were welded and examined with hydrostatic tests and tensile test. The process was accomplished by varying one of the parameters (rotation speed) and keeping the others as constants.