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 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.