Validation of Maximum Temperature during Friction Stir Welding of Butt Joint of Aluminium Alloy by using HyperWorks

Abstract

During friction stir welding, the maximum temperature at tool workpiece interphase within acceptable limit is responsible for sound quality of FSW joint. The prediction of temperature distribution is an essential aspect in order to perform the process of friction stir welding successfully. The maximum temperature along the weldline is governed by several process parameters. In the present study, simulation of friction stir welding process is conducted using HyperWorks. The virtual experiment of friction stir welding process is performed for the butt joint of Aluminium alloy AA6061 material plates. The model predictions and results were validated with experimental data obtained from work of Zhili Feng et. al. The simulation results are in good agreement with that of experimental results. It is also observed that the temperature distribution in the FSW process is symmetrical along the welding line. Simulation performed on HyperWorks has opened new track of modeling and simulation of friction stir welding.

Effect of Process Parameters on Temperature Distribution, Strain Rate and Flow-Stress During Friction Stir Welding of Aluminium Alloy

“…The schematic model of friction stir welding [5] Abdul Arif, et al [1] developed a finite element simulation with improved potential for the prediction of temperature during friction stir welding of aluminium alloy. They validated their developed model by comparing the results of with the experimental data.…”

“…They selected lower rotational and transverse speed based on the suitability of machine.. M.A. Siddiqui et al [7] performed simulation of friction stir welding for the butt joint of Aluminium alloy AA6061 and results were validated with experimental data obtained from work of Zhili Feng et al [15]. M.A.…”

“…M.A. Siddiqui et al [8] conducted virtual experiment of friction stir welding through HyperWorks for variable tool rotational speeds with constant travelling speed showed the variation in temperature distribution along the weld line of butt joint. M.A.…”