Abstract
Friction Stir (FS) welding offers a number of advantages over the conventional fusion welding process, and it is used to join aluminum alloys that are difficult to weld by fusion welding processes. It has compatibility to any alloy composition, and produces the welded joints by eliminating the defects with improved mechanical properties. The weld quality is mainly influenced by the heat generated and material flow pattern that takes place during the friction stir welding process which depends on the above mentioned parameters. The mechanical and micro structural properties are highly influenced by the heat generation and material flow patterns. The tool geometry plays a vital role in the heat generation and material flow. The aim of the research is to study the influence of tool geometry on heat generation and temperature during friction stir welding process. A comparative study has been done based on the results obtained from numerical analysis and experimentation. It was found that the dissimilar FS welded joints fabricated using hexagonal tool pin profile generates optimum heat generation and temperature required for formation of quality weld irrespective of other process parameter.
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