The weld properties of friction stir welding remains as an area of interest with respect to the effect of tool geometry and process parameters. In the present investigation effort has been made to understand the effect of important welding parameters such as tool rotational speed, traverse speed and probe geometries on various mechanical properties of AA1100 aluminium alloys. Ultimate tensile strength, percentage of elongation and hardness were determined experimentally for this purpose. Analysis of variance (ANOVA) was used to observe the main effect of above mentioned parameters on mechanical properties. A regression relationships were developed to predict each output. The experimental and predicted values from the mathematical model were in close agreement.
The present investigation describes a computational fluid dynamics approach to study the effects of friction stir welding tool profiles on the thermal conditions and material flow in welds. The aim is to observe the temperatures of the weld and material flow with respect to different probe profiles. For the modeling purpose, temperature dependent material properties and stick-slip conditions between the tool and work material were incorporated. The results from the model exhibited most of the process characteristics of friction stir welding, such as the difference in temperatures of advancing and retreating sides of the weld, temperature contours ahead and behind the tools along the weld, and flow fields. The thermal condition exhibited temperatures that were close to experimental values and below the melting point of the aluminum alloy.
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