Abstract
Friction stir welding (FSW) is a solid-state welding process that is gaining importance in recent times due to better control of microstructure. In the present work, a thermo-mechanical model is developed for FSW and under water friction stir welding (UFSW) of AA 6063-T6. Temperature dependent viscosity is considered as thermo physical property along with constant values of thermal conductivity and specific heat. Fine mesh is used for complex parts of tool to obtain good results. Rotational speed of tool, feed rate and plunge pressure are taken as influencing parameters for study. Partial stick-slip boundary condition is taken between the tool and work piece interfaces. Experiments were carried out for validation of model. The results of thermal and material flow histories are extracted. Results shows the significant differences in peak temperature of FSW and UFSW along with reduction in heat affected zone in UFSW whereas results of material flow velocity underlined the differences between the FSW and UFSW in term of peak values of stir velocities with the change in influencing parameters.
Highlights
Welding employs heat and/or pressure to achieve a sound joint
Validation is performed at constant feed rate and plunge pressure of 22 mm/min and 17 MPa respectively
The experimental and numerical values of temperature along with percentage error for both Friction stir welding (FSW) and Under water friction stir welding (UFSW) are given in table 5
Summary
Welding employs heat and/or pressure to achieve a sound joint. Friction stir welding (FSW) is the non-fusion solid-state welding process that uses both heat and pressure. Mohammadi et al [8] studied the effect of tool geometry, rotation speed and feed rate on properties of dissimilar magnesium/ aluminium friction stir welded lap joints. Modelling and Simulation of Friction Stir Welding and Under Water Friction Stir Welding of Al6063 Alloy that increase in rotation speed to 1400 rpm and feed rate to 40 mm/min respectively, tensile strength and ductility of joint increases. Fu et al [19] observed tensile strength improvement by reduction in Width of Heat affected zone (HAZ) in UFSW They studied the temperature distribution and mechanical properties of AA 7050. Thermal and material flow histories are taken as results for comparison
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