Simulation of temperature distribution and heat generation during dissimilar friction stir welding of AA6061 aluminum alloy and Al-Mg2Si composite

Ebtesam Sharghi,Ali Farzadi

doi:10.1007/s00170-021-08175-z

Ebtesam Sharghi, Ali Farzadi

Open Access

https://doi.org/10.1007/s00170-021-08175-z

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Abstract

During dissimilar friction stir welding (FSW) of Al-Mg2Si metal matrix composite and AA6061 aluminum alloy, the temperature field and heat generation were investigated using a 3-dimensional computational fluid dynamics (CFD) model and FLUENT software. The simulations were conducted for rotational speeds of 720, 920, and 1120 rpm. The welding experiments were carried out to validate the simulation results. About 70% of the heat is generated at the interface between the shoulder and the workpiece. The maximum temperature is predicted on the advancing side (AS). The difference between the peak temperatures on the AS and the retreating side (RS) is about 115 K. The effect of the rotational speed on the peak temperature is significant. The temperature distribution in the cross sections is asymmetric, which originates from different material velocities on the AS and RS. The peak temperature on the RS develops under the top surface, while the peak temperature on the AS develops on the surface.

Highlights

In recent decades, friction stir welding (FSW), a solid-state technique, has been highly considered due to its advantages over fusion welding methods
This study showed that the temperature distribution is asymmetrical, and the maximum temperature, which decreases with increasing the welding speed, is about 80 to 90% of the base metal melting point
The calculated and the experimental thermal cycles were in good agreement

Summary

Introduction

Friction stir welding (FSW), a solid-state technique, has been highly considered due to its advantages over fusion welding methods. This welding method is a green technology and has high energy efficiency. The joint of an alloy and a metal matrix composite (MMC) is one kind of useful dissimilar joints. The potential properties such as high strength and low density can be applied using a dissimilar joints in the critical parts. Efficiency will improve, and costs will reduce [4]

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