Predication of temperature distribution and strain during FSW of dissimilar Aluminum alloys using Deform 3D

Abstract

Dissimilar aluminium alloy plates AA6061 and AA5052 were subjected to friction stir welding (FSW) in order to examine the effect of heat generation on the welding process. Thermocouples were used to measure the temperature distribution on the workpiece during welding and it was found that the advancing side had higher temperatures than the receding side. The FSW process was simulated at tool speeds of 1000, 1200, and 1400 rpm, as well as feed rates of 20, 40, and 60 mm/min. The tests were designed using the Taguchi OA. AA6061 identical welds show a small reduction in grain size at the HAZ, but AA5052 and AA6061 dissimilar welds show much larger grain sizes at the weldment than the base metal. While keeping a consistent feed rate, the tool speed was found to boost weld zone heat generation. It is possible to reduce the amount of heat generated in weld zones by increasing the feed rate while maintaining consistent tool rotation rates. Analysis of variance (ANOVA) demonstrated that the advancing side, retreating side as D1F3S1, and total heat generation is D1F3S3 (i.e., distance from the welded zone is 20 mm, feed rate at 60 mm/min, and tool speed at 1000 rpm) is the ideal temperature distribution and heat generation condition. For FSW, Deform-3D software was used to create a model of the workpiece and tool. Thermal analysis was performed to determine the temperature distribution throughout each part of the workpiece.