In the present work, an attempt was made to develop high temperature wear resistant hardfaced tools for friction stir welding
(FSW) of commercial grade copper alloys. Hardfacing was applied on mild steel rod using chromium carbide forming powder
by plasma transferred arc (PTA) hardfacing process and chromium carbide forming consumables by Shielded Metal Arc (SMA)
hardfacing process. Commercially available tool material super high speed steel (SHSS) was also used to friction stir weld
copper alloy for comparison purpose. From this investigation, it is found that the PTA hardfaced tool yielded defect free joints
without tool wear compared with other tools.