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Numerical and Experimental Thermal Studies on Friction Welding of AA6061 Plate and AA1060 Tube Using External Tool

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Abstract

Friction welding of tube-to-tube plate using external tool has earned prominent research interests due to its versatility and joint integrity. Hitherto, this process was studied primarily on the mechanical properties. This work presents the thermal studies of this process using analytical model and 3-D Finite Element Method-based numerical models. Infrared Thermography-based experimental temperature measurement has been done to verify the results in the case of AA 6061 plate and AA 1060 tube joints. Results for various parametric conditions show a good agreement with the corresponding FE simulation results. This study shows the temperature history of the process and explains the effect of frictional heat generation on the temperature attained by the material. With FE results, the internal temperature distribution of the material is explained. It is also revealed that tool rotation speed, plunge duration and total welding rotation strongly influence the peak temperature of the materials.

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Acknowledgements

The authors put on records sincere thanks to the Dept. MME, NIT Trichy as well as Prof.G.Phanikumar, Dept. of MME, IIT Madrass for the supports extended towards this work.

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Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, National Institute of Technology Trichy, Trichy, 620015, India

    Deepesh Vimalan, Amal Purushothaman & Shanmugam Muthukumaran

  2. Department of Physics, National Institute of Technology Trichy, Trichy, 620015, India

    Dillibabu Sastikumar

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  1. Deepesh Vimalan
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  2. Amal Purushothaman
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  3. Shanmugam Muthukumaran
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  4. Dillibabu Sastikumar
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Correspondence to Deepesh Vimalan.

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Vimalan, D., Purushothaman, A., Muthukumaran, S. et al. Numerical and Experimental Thermal Studies on Friction Welding of AA6061 Plate and AA1060 Tube Using External Tool. Trans Indian Inst Met (2024). https://doi.org/10.1007/s12666-023-03184-w

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