Aluminium alloys are widely used in automotive, aerospace and ship industries as high strength-to-weight ratio materials. With the increasing demand for lightweight components, their application is becoming more extensive. To study the effect of Tool geometries on Metallurgical & mechanical properties of Aluminum alloy 5052 H32 using friction stir welding process. To briefly discuss about the conditions & conclude the suitable condition for Aluminium alloy 5052 H32. To plot and conclude the hardness values for various conditions. The tool material Mild Steel IS 2062 FE410 cone type and thread type has been selected for this research for various speeds to find suitable condition. The micro structure and macro structure have checking the structural formation of welded area in details to know it the strength of the joining. The present friction stir welding research is implementing the new tools for the current issues; here we try to implement new material for already available tools.

The dissimilar material welding at lower expensive is one of the popular techniques which are used in power generation services such as mining, petro chemical refineries and mineral processing plant as well as recuperator in furnace system. For these applications, the insulation plays an important role for effective result. Fluid flow from one medium to another medium is carried out through insulation materials to prevent the transmission of excessive heat. If it gets wet, it loses all its insulation properties. It is easily crushed if the pipe gets stepped on. The materials serves important role to save the heat energy in operating and constructing the power plant. In this research work, mild steel and stainless steel SS 409 are welded together by ER 309 L electrode by TIG welding process to achieve these applications. Service temperature is sensible; inside temperature is maintained low because of rapid cooling. This research concludes that, insulation material is not necessary for dealing out the material (below 700°C). Stainless steel SS 409 tends to contract and expand more and serves as good corrosion resistant material at the service temperature. Mild steel is a good heat conductor; it cools quickly and contract earlier as the joint cools and the heat is removed from the metal surface.