Heat transfer analyses in friction stir welding of aluminium alloy

Abstract

This work is aimed to develop a heat transfer model of friction stir welding process and subsequently to utilize the same for transient thermal analysis under differential influence of process parameters. The heat generation is assumed due to friction and plastic deformation at the tool–workpiece interface. A contact state variable is defined to estimate the amount of heat generation due to plastic deformation. The symmetric heat flux at the interfaces of flat tool shoulder surface, tool pin side, and bottom surfaces acts as heat input to the system by neglecting the effect of transverse tool speed. The heat generation from both the side and bottom surfaces of pin plays a significant role for the development of the temperature. Thermal history of friction stir welded AA1100 and AA6061 is estimated by developed numerical model and is compared with experimental results under similar welding conditions, thus validating the developed model. The experiments reveal that the temperature distributions are not symmetric with respect to welding line and maximum temperature occurs behind the tool pin. With the addition of heat generation due to plastic deformation, the heat transfer model precisely predicts the maximum temperature and time–temperature profiles at different welding conditions.

Effect of process parameters on temperature and force distribution during friction stir welding of armor-marine grade aluminum alloy

“…Besides this, literature reports the application of temperature and force distribution during the process. 9–16 Yaduwanshi et al 9 developed a numerical model of heat generation during the FSW process and compared with experimental results under similar working conditions. It is found that the temperature distribution is non-symmetrical in nature with respect to the welding line, and maximum temperature is obtained at behind the tool pin.…”

Effect of plasma preheating on weld quality and tool life during friction stir welding of DH36 steel

“…22 Ahmad et al 23 found that laser assisted FSW reduced up to 55% of the plunging force in FSW of steel. Yaduwanshi et al 24 investigated plasma assisted FSW (PFSW) of softer materials like aluminum alloys. They reported superior mechanical properties and high process temperature in PFSW.…”

Effect of friction stir welding tool design on welding thermal efficiency

“…Since the invention of FSW, many scientific research articles on the heat transfer of the process have been published [5][6][7][8][9] and have mainly focused on the heat generation mechanism, experimental measurement of temperature, in addition to the analytical and numerical modelling of the heat transfer behaviour. However, a limited body of work has been published on the welding thermal efficiency or on ways of enhancing it.…”