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Thermal analysis of friction stir welding process and investigation into affective parameters using simulation

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Abstract

Friction stir welding (FSW) as an efficient solid state joining process has numerous applications in industries. Temperature distribution analysis through simulation not only brings the possibility to characterize the microstructure of different zones, but also enables one to save cost and energy as optimum welding variables are obtained with less concern. In the present study, the temperature distribution during the friction stir welding (FSW) process of AA6061-T6 was evaluated using finite element method (FEM). Since experimental measurements cannot be readily made in the weld region, it is difficult to understand physics in the stir zone of the welds without simulation. Abaqus software was applied to model the parts and simulate the process of welding, while Johnson-Cook law utilized to evaluate the effect of strain rate and generated heat. FE-results were verified by experimental results. The comparisons revealed a good compatibility between the results. The effect of probe shape on temperature distribution was also studied. It was found that spherical pins result in the highest temperatures at workpieces with respect to cylindrical and tapered pins. Additionally, it was concluded that more heat is generated in workpieces as pin angle increases.

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Authors and Affiliations

  1. Faculty of Engineering, University of Kashan, Kashan, Iran

    Mahmoud Abbasi

  2. Department of Mining and Metallurgy, Amirkabir University of Technology, Tehran, Iran

    Behrouz Bagheri

  3. Department of Material Engineering, Islamic Azad University (Science and Research Branch), Tehran, Iran

    Rasoul Keivani

Authors
  1. Mahmoud Abbasi
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  2. Behrouz Bagheri
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  3. Rasoul Keivani
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Correspondence to Behrouz Bagheri.

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Recommended by Associate Editor Yong-Tae Kim

Behrouz Bagheri graduated from Amirkabir University of Technology, Tehran, Iran in 2011. He took his master degree in Materials science and Engineering. Simulation of metal forming and welding processes are his main research fields of study.

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Abbasi, M., Bagheri, B. & Keivani, R. Thermal analysis of friction stir welding process and investigation into affective parameters using simulation. J Mech Sci Technol 29, 861–866 (2015). https://doi.org/10.1007/s12206-015-0149-3

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  • DOI: https://doi.org/10.1007/s12206-015-0149-3

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