Abstract

AbstractMaterial flow behavior of AA6061-T6 aluminum alloy during friction stir welding (FSW) is computationally investigated in the present study. Eulerian approach is considered in the computational simulation assuming that the tool rotates at a fixed location and material flows at a constant speed. A flat cylindrical tool profile is used to investigate the material flow at different tool rotational speed during friction stir welding (FSW) of the alloy. Temperature contours for different rotational speed reveal that temperature distribution near the tool improved as tool rotational speed increases and temperature decreases as distance from center of tool increases. Velocity contours depict that the plasticized material moves around the tool and maximum velocity is observed when the tool rotates at 1200 rpm. Mixing of plastically deformed material around the tool governs the welding quality. This study suggest that tool rotation influence the material flow during FSW. Higher tool rotation gives improved temperature distribution and material mixing which leads to improved weld quality.KeywordsFriction stir welding (FSW)Numerical simulationMaterial flow

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