Abstract
The objective of this research is to investigate the effect of process parameters during friction-stir welding (FSW) of aluminium alloy (Al6061) on welding peak temperature. A three-dimensional thermo-mechanical model for FSW was developed using COMSOL Multiphysics software. The simulated temperature profile was validated with the existing experimental result, which is in good agreement with the experimental result. The effect of process parameters such as rotational speed, welding speed, and normal force on the peak temperature was studied using the validated model. The process parameters in the simulation were varied according to the Taguchi L9 orthogonal array. The optimum process parameters were calculated corresponding to the minimum and maximum temperature during the FSW of Al6061. The percentage contribution of each parameter has been studied using analysis of variance (ANOVA). The results show that the normal force contributes more to the welding temperature than the rotational speed and the welding speed.
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