-FEA analysis will be performed for friction stir welding of aluminum 6061 and aluminum 7475 at different speeds using ANSYS. Coupled field analysis, thermal and structural will be performed. A parametric model with the weld plates and cutting tool will be done in Pro/Engineer. The speeds are 750rpm, 560 rpm and 410rpm. The effects of different tool pin profiles on the friction stir welding will also be considered for analysis. Tool pin profiles are circular. In this thesis, the static analysis is to determine the deformation, stress and strain at different speeds (750,560 & 410 rpm) of the cutting tool. And thermal analysis is to determine the heat flux and temperature distribution. The two process parameters i.e. Circular pin profile and rotational speed.It is found that the joint fabricated using round screw thread pin exhibits superior tensile properties, impact and hardness.
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