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A three-dimensional (3D) finite element model was created to simulate the friction stir welding process of 6063-T5 aluminum alloy. The analysis studies the fundamental knowledge of FSW process with respect to temperature difference in material to be joined and to simulate the temperature distribution in the workpiece as a result of a Friction Stir Welding. The simulation uses HyperMesh and HyperView solver from Altair Hyperworks.  The simulation provides better understanding for the peak temperature distribution in the friction stir process. Two cases have (i) constant traverse speed, but varying been simulated rotational speed, and (ii) constant rotational speed, but varying traverse speeds. Simulation results show the peak temperatures increased when the traverse and rotational speeds were increased.

Friction stir welding (FSW) is a promising joining process that offers a high potential to be widely applied across industry sectors such as automotive, shipbuilding and aerospace. Nevertheless the path force can vary significantly due to the fluctuation of workpiece temperature and other process variations, thus results in inconsistency in weld microstructure. This paper describes the system integration of a FSW machine with a focus on the development of a traverse controlled table in order to produce a consistent temperature and path force along the weld path in FSW process. Aluminium alloy 6061 plate and a FSW’s tool with a flat shoulder and conical pin without thread are used. Advantages of such an approach include wormhole generation will be eliminated, a high quality of weld microstructure can be produced and the synchronization between the temperature and path force can be obtained.