Heat transfer modeling of dissimilar FSW of Al 6061/AZ31 using experimentally measured thermo-physical properties

  • Amit Kumar Singh
  • Pankaj Sahlot
  • Manas Paliwal
  • Amit AroraEmail author


A heat transfer numerical model is developed for friction stir welding of dissimilar materials Al 6061 and AZ31 alloy. Thermo-physical properties were experimentally determined for the stir zone and compared with the base alloys. Experimentally determined thermo-physical properties of the stir zone are not strictly the average values of the base alloys but exhibit a complex relationship with the microstructural features and the intermixing of Al and Mg in the weld region. The numerical model is employed to predict the temperature distribution on the advancing and retreating side. A good agreement between computed and experimentally measured results was obtained at 24-mm, 20-mm, and 16-mm tool shoulder diameter. The proposed model can be used to predict the thermal cycle, peak temperature, and thermo-mechanically affected zone for welding of dissimilar materials on friction stir welding.


Dissimilar weld Friction stir welding Intermixing Numerical modeling Thermo-physical properties 



The authors would like to thank Prof. Satish Vitta, Metallurgical Engineering and Materials Science IIT Bombay, for his help with thermal diffusivity measurement. The authors would also like to acknowledge Mr. Aroh Shrivastava, Institute for Plasma Research, for his help in specific heat capacity measurement.

Funding information

This study was funded by the Board of Research in Nuclear Sciences (BRNS) (project number 57/14/05/2019-BRNS) and Science and Engineering Research Board (SERB) (project number CRG/2018/004944).


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Amit Kumar Singh
    • 1
  • Pankaj Sahlot
    • 1
    • 2
  • Manas Paliwal
    • 1
  • Amit Arora
    • 1
    Email author
  1. 1.Materials Science and EngineeringIndian Institute of Technology GandhinagarGandhinagarIndia
  2. 2.Mechanical Engineering, School of TechnologyPandit Deendayal Petroleum UniversityGandhinagarIndia

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