Numerical Simulation of Heat Transfer Behavior of Dissimilar AA5052-AA6061 Plates in Fiction Stir Welding: An Experimental Validation

Abstract

Fiction Stir welding (FSW) a unique type of metal joining process in solid state, where the heat generation takes place due to the friction action between the rotating tool and the work piece. It is generally used to join all series of Aluminum alloys with good strength and other metallic alloys finds difficult to weld through regular fusion welding techniques. The metal joining takes place in the solid state as the metal to be welded reaches about 80% to 90% of its melting temperature. The joining of metals in friction stir welding does not require any filler metals all classes of Aluminium alloys can be joined and in some desirable cases dissimilar metal compositions and Aluminiun metals composites can be joined satisfactorily. Joining of dissimilar metals has become a trend in the industries like aerospace, automotive chemical etc. as the helps in reducing the cost incurred by eliminating the costly materials. In the present study an experimental investigations are made to study the heat transfer behavior by determining the temperature distribution in AA5052-AA6061 plates during the Friction Stir welding. A three dimensional transient analysis is made by using ANSYS finite element analysis software. Thermocouples are placed at the suitable locations and the same point the temperature readings were taken from the simulation results. The experimental data is compared with the numerically simulated results. The numerical simulations results obtained are in better agreement with the experimental data obtained.

Numerical Simulation of Heat Treatment Process of Aluminium Profiles

“…1. The physical parameters of the aluminium profile are shown in the Tab 2 [4,5,10]. Transient analysis, which took approximately 3 days, was performed for initialization.…”

“…where Cp is specific heat capacity of water and air mixture defined by (9);  is dynamic viscosity of water and air mixture defined by (10); ( , ) is kinematic viscosity of water and air mixture defined by (11), is the mean value of a fluid velocity as a function of a distance from the nozzle orifice and a radius defined by (12) and d is hydraulic diameter.…”

“…Cooling of profile surfaces is performed by water spray, which is created by mixing water and an air in nozzles [11]. The total number of nozzles actively involved in this mixing process depends on the operational conditions of the WQ and could be around one thousand of nozzles.…”

Temperature Analysis of Friction Stir Welding (AA6061-T6) with Coupled Eulerian-Lagrangian Approach.

“…In this study, the effect of heat conduction to the backplate, and temperature generated in the FSW process were examined. Vishwanath et al [16] studied a 3-D transient analysis by using ANSYS. In the simulation of the AA6061 plate, the temperature rise is 339°C, which is recorded by attaching a thermocouple 12mm away from the weld line and 291°C by placing 16mm away from the weld line.…”

Machine Learning Algorithm for Surface Quality Analysis of Friction Stir Welded Joint

“…Mishra et al [14] used the convolutional neural network to separate the texture of the Friction Stir Welded joint from the common welded joint. [15] In the recent work, Fourier transformation which is a Computer vision tool utilized by using Python programming executed on Google Colaboratory platform for the edge detection of Friction Stir Welded joints.…”